1999-2002 ISUZU EXP UBS WORKSHOP MANUAL – PDF DOWNLOAD
recommended. Park vehicle on level ground, “block” front or rear wheels, set jack against the recommended lifting points (see “Lifting Instructions” in this section), raise vehicle and support with chassis stands and then perform the service operations. 2. Before performing service operations, disconnect ground cable from the battery to reduce the chance of cable damage and burning due to short circuiting. 3.
Use a cover on body, seats and floor to protect them against damage and contamination. 4. Brake fluid and anti–freeze solution must be handled with reasonable care, as they can cause paint damage. 5. The use of proper tools and recommended essential and available tools, where specified, is important for efficient and reliable performance of service repairs. 6. Use genuine Isuzu parts. 7. Used cotter pins, plastic clips, gaskets, O–rings, oil seals, lock washers and self–locking nuts should be discarded and new ones should be installed, as normal function of the parts cannot be maintained if these parts are reused.
8.To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nuts separate is very important, as they vary in hardness and design depending on position of installation. 9. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air, and make certain they are free from restrictions. 10.
Lubricate rotating and sliding faces of the parts with oil or grease before installation. 11. When necessary, use a sealer on gaskets to prevent leakage. 12. Carefully observe all specifications for bolt and nut torques. 13. When removing or replacing parts that require refrigerant to be discharged from the air conditioning system, be sure to use the Vehicle Refrigerant Recovery and Recycling Equipment (VRRRE) to recover and recycle Refrigerant–134a. 14.
When a service operation is completed, make a final check to be sure the service has been done properly and the problem has been corrected. 15.SUPPLEMENTAL RESTRAINT SYSTEM The vehicle is equipped with a Supplemental Restraint System (SRS) – Air Bags. This system is not to be serviced without consulting the appropriate service information.
Consult Section 9J “SRS System” if work is to be done on the front of the vehicle such as bumper, sheet metal, seats, wiring, steering wheel or column. Also review SRS system information if any arc welding is to be done on the vehicle. The SRS system equipped vehicle can be identified by: 1. “AIR BAG” warning light on the instrument cluster. 2. A Code “J” for fifth digit of Vehicle Identification Number.
TABLE OF CONTENTS:
1999-2002 ISUZU EXP UBS WORKSHOP MANUAL – PDF DOWNLOAD
TOP............................................................................................................................................................. 0
US VERSION.................................................................................................................................................. 2
1999 MODEL.............................................................................................................................................. 2
(UX) TROOPER........................................................................................................................................ 2927
Sec.0 GENERAL INFORMATION..................................................................................................................... 2928
0A GENERAL INFORMATION.................................................................................................................... 2928
General Repair Instruction.............................................................................................................. 2928
Illustration Arrows..................................................................................................................... 2929
Identification.......................................................................................................................... 2930
Theft Prevention Standard............................................................................................................... 2932
Lifting Instructions.................................................................................................................... 2937
Standard Bolts Torque Specifications.................................................................................................... 2940
Abbreviations Charts.................................................................................................................... 2941
Service Parts Identification Plate...................................................................................................... 2942
0B MAINTENANCE AND LUBRICATION............................................................................................................ 2943
Maintenance Schedule List............................................................................................................... 2943
Explanation of Complete Vehicle Maintenance Schedule.................................................................................... 2946
Recommended Fluids and Lubricants................................................................................................... 2949
Lubricant Viscosity Chart............................................................................................................... 2950
Recommended Liquid Gasket........................................................................................................... 2952
Recommended Thread Locking Agents................................................................................................... 2953
Maintenance Service Data................................................................................................................ 2954
Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................................................ 2955
1A HVAC SYSTEMS........................................................................................................................... 2955
Service Precaution...................................................................................................................... 2956
Heating and Ventilation System.......................................................................................................... 2956
General Description..................................................................................................................... 2956
Wiring Diagram.......................................................................................................................... 2961
Diagnosis............................................................................................................................... 2962
Individual Inspection................................................................................................................... 2965
Heater Unit............................................................................................................................. 2968
Heater Unit and Associated Parts.................................................................................................... 2968
Removal............................................................................................................................. 2968
Installation........................................................................................................................ 2969
Heater Core and / or Mode Door.......................................................................................................... 2970
Disassembled View................................................................................................................... 2970
Removal............................................................................................................................. 2970
Inspection.......................................................................................................................... 2971
Installation........................................................................................................................ 2971
Heater Mode Control Link Unit........................................................................................................... 2972
Disassembled View................................................................................................................... 2972
Removal............................................................................................................................. 2972
Installation........................................................................................................................ 2973
Heater Temperature Control Link Unit.................................................................................................... 2973
Disassembled View................................................................................................................... 2973
Removal............................................................................................................................. 2973
Installation........................................................................................................................ 2973
Blower Assembly......................................................................................................................... 2974
Blower Assembly and Associated...................................................................................................... 2974
Removal............................................................................................................................. 2974
Installation........................................................................................................................ 2975
Blower Link Unit and / or Mode door..................................................................................................... 2975
Disassembled View................................................................................................................... 2975
Removal............................................................................................................................. 2975
Installation........................................................................................................................ 2976
Blower Motor............................................................................................................................ 2977
Blower Motor and Associated Parts................................................................................................... 2977
Removal............................................................................................................................. 2977
Installation........................................................................................................................ 2977
Rear Heater Duct, Defroster Nozzle and Ventilation Duct................................................................................. 2978
Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts........................................................... 2978
Removal............................................................................................................................. 2978
Installation........................................................................................................................ 2979
Center and / or Drive Side Vent......................................................................................................... 2979
Center Vent, Drive Side Vent and Associated Parts................................................................................... 2979
Removal............................................................................................................................. 2979
Installation........................................................................................................................ 2979
Control Lever Assembly and / or Control Cable........................................................................................... 2980
Control Lever Assembly, Control Cable and Associated Parts.......................................................................... 2980
Removal............................................................................................................................. 2980
Installation........................................................................................................................ 2981
Control Panel Illumination Bulb......................................................................................................... 2982
Control Panel Illumination Bulb and Associated Parts................................................................................ 2982
Removal............................................................................................................................. 2982
Installation........................................................................................................................ 2982
Resistor................................................................................................................................ 2983
Resistor and Associated Parts....................................................................................................... 2983
Removal............................................................................................................................. 2983
Installation........................................................................................................................ 2983
Air Conditioning System................................................................................................................. 2984
General Description................................................................................................................. 2984
Wiring Diagram...................................................................................................................... 2990
Diagnosis........................................................................................................................... 2993
Individual Inspection............................................................................................................... 3001
General Repair Procedure............................................................................................................ 3002
Compressor Assembly..................................................................................................................... 3009
Compressor Assembly and Associated Parts............................................................................................ 3009
Removal............................................................................................................................. 3009
Installation........................................................................................................................ 3010
Condenser Assembly...................................................................................................................... 3011
Condenser Assembly and Associated Parts............................................................................................. 3011
Removal............................................................................................................................. 3011
Installation........................................................................................................................ 3011
Receiver / Drier........................................................................................................................ 3012
Receiver / Drier and Associated Parts............................................................................................... 3012
Removal............................................................................................................................. 3012
Installation........................................................................................................................ 3012
Pressure Switch......................................................................................................................... 3013
Pressure Switch and Associated Parts................................................................................................ 3013
Removal............................................................................................................................. 3013
Installation........................................................................................................................ 3013
Evaporator Assembly..................................................................................................................... 3014
Evaporator Assembly and Associated Parts............................................................................................ 3014
Removal............................................................................................................................. 3014
Installation........................................................................................................................ 3015
Electronic Thermostat, Evaporator Core and/or Expansion Valve........................................................................... 3015
Disassembled View................................................................................................................... 3015
Removal............................................................................................................................. 3015
Installation........................................................................................................................ 3016
Air Conditioning Switch and Illumination Bulb........................................................................................... 3017
Air Conditioning Switch, Illumination Bulb and Associated Parts..................................................................... 3017
Removal............................................................................................................................. 3017
Installation........................................................................................................................ 3017
Refrigerant Line........................................................................................................................ 3018
Refrigerant Line and Associated Parts............................................................................................... 3018
Removal............................................................................................................................. 3018
Installation........................................................................................................................ 3019
Main Data And Specifications............................................................................................................ 3020
Compressor.............................................................................................................................. 3022
Service Precaution.................................................................................................................. 3022
General Description................................................................................................................. 3022
Metric Thread Size Information...................................................................................................... 3024
Compressor Clutch Plate and Hub Assembly................................................................................................ 3024
Removal............................................................................................................................. 3024
Installation........................................................................................................................ 3024
Compressor Clutch Rotor and/or Bearing.................................................................................................. 3025
Removal............................................................................................................................. 3025
Installation........................................................................................................................ 3025
Compressor Clutch Coil.................................................................................................................. 3026
Removal............................................................................................................................. 3026
Installation........................................................................................................................ 3027
Compressor Shaft Seal................................................................................................................... 3028
Service Precaution.................................................................................................................. 3028
Seal Leak Detection................................................................................................................. 3028
Removal............................................................................................................................. 3028
Cleaning............................................................................................................................ 3029
Installation........................................................................................................................ 3029
Compressor Pressure Relief Valve........................................................................................................ 3030
Removal............................................................................................................................. 3030
Installation........................................................................................................................ 3030
Compressor Oil.......................................................................................................................... 3030
Compressor Oil Check................................................................................................................ 3030
Checking and Adjusting Oil Quantity for Used Compressor............................................................................. 3030
Checking and Adjusting for Compressor Replacement................................................................................... 3030
Contamination of Compressor Oil..................................................................................................... 3031
Oil Return Operation................................................................................................................ 3031
Replacement of Component Parts...................................................................................................... 3031
Bench-Check Procedure............................................................................................................... 3031
Special Tools........................................................................................................................... 3033
Sec.2 STEERING................................................................................................................................ 3035
2A POWER ASSISTED SYSTEM.................................................................................................................. 3035
Service Precaution...................................................................................................................... 3036
General Description..................................................................................................................... 3036
Diagnosis............................................................................................................................... 3039
Power Steering System Test.............................................................................................................. 3045
Maintenance............................................................................................................................. 3046
Fluid Level............................................................................................................................. 3046
Bleeding The Power Steering System...................................................................................................... 3046
Bleeding Procedure...................................................................................................................... 3046
Flushing The Power Steering System...................................................................................................... 3046
Steering Wheel Free Play Adjustment..................................................................................................... 3047
Front End Alignment Inspection and Adjustment........................................................................................... 3047
Main Data and Specifications............................................................................................................ 3052
Special Tools........................................................................................................................... 3053
Power Steering Gear..................................................................................................................... 3054
Power Steering Gear and Associated Parts............................................................................................ 3054
Removal............................................................................................................................. 3054
Installation........................................................................................................................ 3055
Steering Gear Disassembled View..................................................................................................... 3056
Disassembly......................................................................................................................... 3057
Inspection and Repair............................................................................................................... 3058
Reassembly.......................................................................................................................... 3059
Main Data and Specifications........................................................................................................ 3061
Power Steering Pump..................................................................................................................... 3062
Power Steering Pump and Associated Parts............................................................................................ 3062
Removal............................................................................................................................. 3062
Installation........................................................................................................................ 3063
Power Steering Pump Disassembled View............................................................................................... 3064
Disassembly......................................................................................................................... 3064
Inspection and Repair............................................................................................................... 3065
Reassembly.......................................................................................................................... 3066
Main Data and Specifications........................................................................................................ 3067
Center Track Rod Assembly............................................................................................................... 3068
Center Track Rod Assembly and Associated Parts...................................................................................... 3068
Removal............................................................................................................................. 3069
Inspection and Repair............................................................................................................... 3069
Installation........................................................................................................................ 3069
Outer Track Rod Assembly................................................................................................................ 3070
Outer Track Rod Assembly and Associated Parts....................................................................................... 3070
Removal............................................................................................................................. 3071
Inspection and Repair............................................................................................................... 3071
Installation........................................................................................................................ 3072
Relay Lever............................................................................................................................. 3073
Relay Lever and Associated Parts.................................................................................................... 3073
Removal............................................................................................................................. 3073
Installation........................................................................................................................ 3074
Steering Linkage and Associated Parts................................................................................................... 3075
Main Data and Specifications........................................................................................................ 3075
Special Tools........................................................................................................................... 3076
Supplemental Restraint System Steering Wheel & Column................................................................................... 3077
Service Precaution.................................................................................................................. 3077
SRS Connectors...................................................................................................................... 3077
Inflator Module......................................................................................................................... 3079
Inflator Module and Associated Parts................................................................................................ 3079
Removal............................................................................................................................. 3079
Inspection and Repair............................................................................................................... 3080
Installation........................................................................................................................ 3080
Steering Wheel.......................................................................................................................... 3081
Steering Wheel and Associated Parts................................................................................................. 3081
Removal............................................................................................................................. 3081
Installation........................................................................................................................ 3083
Combination Switch...................................................................................................................... 3084
Combination Switch and Associated Parts............................................................................................. 3084
Removal............................................................................................................................. 3084
Installation........................................................................................................................ 3086
Lock Cylinder........................................................................................................................... 3088
Lock Cylinder and Associated Parts.................................................................................................. 3088
Removal............................................................................................................................. 3088
Installation........................................................................................................................ 3090
System Inspection................................................................................................................... 3091
Steering Column......................................................................................................................... 3092
Steering Column and Associated Parts................................................................................................ 3092
Removal............................................................................................................................. 3092
Inspection.......................................................................................................................... 3094
Installation........................................................................................................................ 3096
System Inspection................................................................................................................... 3097
Supplemental Restraint System Steering Wheel & Column and Associated Parts.............................................................. 3098
Main Data and Specifications........................................................................................................ 3098
Special Tools........................................................................................................................... 3099
Sec.3 SUSPENSION.............................................................................................................................. 3100
3C FRONT SUSPENSION....................................................................................................................... 3100
Service Precaution...................................................................................................................... 3100
General Description..................................................................................................................... 3101
General Diagnosis....................................................................................................................... 3102
Shock Absorber.......................................................................................................................... 3105
Shock Absorber and Associated Parts................................................................................................. 3105
Removal............................................................................................................................. 3105
Inspection and Repair............................................................................................................... 3105
Installation........................................................................................................................ 3105
Stabilizer Bar.......................................................................................................................... 3106
Stabilizer Bar and Associated Parts................................................................................................. 3106
Removal............................................................................................................................. 3106
Inspection and Repair............................................................................................................... 3106
Installation........................................................................................................................ 3106
Torsion Bar............................................................................................................................. 3107
Torsion Bar and Associated Parts.................................................................................................... 3107
Removal............................................................................................................................. 3107
Inspection and Repair............................................................................................................... 3108
Installation........................................................................................................................ 3108
Knuckle................................................................................................................................. 3110
Knuckle and Associated Parts........................................................................................................ 3110
Removal............................................................................................................................. 3110
Inspection and Repair............................................................................................................... 3111
Installation........................................................................................................................ 3111
Upper Control Arm....................................................................................................................... 3113
Upper Control Arm and Associated Parts.............................................................................................. 3113
Removal............................................................................................................................. 3113
Inspection and Repair............................................................................................................... 3114
Installation........................................................................................................................ 3115
Lower Control Arm....................................................................................................................... 3117
Lower Control Arm and Associated Parts.............................................................................................. 3117
Removal............................................................................................................................. 3117
Inspection and Repair............................................................................................................... 3119
Installation........................................................................................................................ 3119
Upper Ball Joint........................................................................................................................ 3121
Upper Ball Joint and Associated Parts............................................................................................... 3121
Removal............................................................................................................................. 3121
Inspection and Repair............................................................................................................... 3122
Installation........................................................................................................................ 3122
Lower Ball Joint........................................................................................................................ 3123
Lower Ball Joint and Associated Parts............................................................................................... 3123
Removal............................................................................................................................. 3123
Inspection and Repair............................................................................................................... 3124
Installation........................................................................................................................ 3124
Main Data and Specifications............................................................................................................ 3125
Special Tools........................................................................................................................... 3126
3D REAR SUSPENSION........................................................................................................................ 3127
Service Precaution...................................................................................................................... 3127
General Description..................................................................................................................... 3128
Coil Spring............................................................................................................................. 3129
Coil Spring and Associated Parts.................................................................................................... 3129
Removal............................................................................................................................. 3129
Inspection and Repair............................................................................................................... 3130
Installation........................................................................................................................ 3130
Shock Absorber.......................................................................................................................... 3131
Shock Absorber and Associated Parts................................................................................................. 3131
Removal............................................................................................................................. 3131
Inspection and Repair............................................................................................................... 3131
Installation........................................................................................................................ 3131
Trailing Link........................................................................................................................... 3132
Trailing Link and Associated Parts.................................................................................................. 3132
Removal............................................................................................................................. 3132
Inspection and Repair............................................................................................................... 3132
Installation........................................................................................................................ 3133
Center Link............................................................................................................................. 3134
Center Link and Associated Parts.................................................................................................... 3134
Removal............................................................................................................................. 3134
Inspection and Repair............................................................................................................... 3134
Installation........................................................................................................................ 3135
Lateral Rod............................................................................................................................. 3136
Lateral Rod and Associated Parts.................................................................................................... 3136
Removal............................................................................................................................. 3136
Inspection and Repair............................................................................................................... 3136
Installation........................................................................................................................ 3137
Stabilizer Bar.......................................................................................................................... 3138
Stabilizer Bar and Associated Parts................................................................................................. 3138
Removal............................................................................................................................. 3138
Inspection and Repair............................................................................................................... 3138
Installation........................................................................................................................ 3139
Main Data and Specifications............................................................................................................ 3140
Special Tools........................................................................................................................... 3142
3E WHEEL AND TIRE SYSTEM.................................................................................................................. 3143
Service Precaution...................................................................................................................... 3143
General Description..................................................................................................................... 3144
Diagnosis............................................................................................................................... 3145
Wheel................................................................................................................................... 3151
Wheel and Associated Parts.......................................................................................................... 3151
Removal............................................................................................................................. 3151
Installation........................................................................................................................ 3151
Tire.................................................................................................................................... 3152
Tire Replacement.................................................................................................................... 3152
General Balance Procedure........................................................................................................... 3152
Balancing Wheel and Tire............................................................................................................ 3153
Main Data and Specifications............................................................................................................ 3154
Sec.4 DRIVELINE/AXLE.......................................................................................................................... 3155
4A1 DIFFERENTIAL (FRONT)................................................................................................................... 3155
Service Precaution...................................................................................................................... 3155
Front Drive Axle........................................................................................................................ 3156
Diagnosis............................................................................................................................... 3156
Pinion Shaft Oil Seal................................................................................................................... 3157
Pinion Shaft Oil Seal and Associated Parts.......................................................................................... 3157
Removal............................................................................................................................. 3157
Inspection and Repair............................................................................................................... 3158
Installation........................................................................................................................ 3158
Front Drive Axle Assembly............................................................................................................... 3159
Front Drive Axle Assembly and Associated Parts...................................................................................... 3159
Removal............................................................................................................................. 3159
Installation........................................................................................................................ 3161
Differential Assembly................................................................................................................... 3163
Disassembled View................................................................................................................... 3163
Disassembly......................................................................................................................... 3163
Reassembly.......................................................................................................................... 3166
Differential Cage Assembly.............................................................................................................. 3175
Disassembled View................................................................................................................... 3175
Disassembly......................................................................................................................... 3175
Inspection and Repair............................................................................................................... 3176
Reassembly.......................................................................................................................... 3177
Main Data and Specifications............................................................................................................ 3179
Special Tools........................................................................................................................... 3181
4A2 DIFFERENTIAL (REAR).................................................................................................................... 3183
Service Precaution...................................................................................................................... 3183
General Description..................................................................................................................... 3184
Diagnosis............................................................................................................................... 3185
Axle Housing............................................................................................................................ 3186
Axle Housing and Associated Parts................................................................................................... 3186
Removal............................................................................................................................. 3186
Oil Seal Replacement................................................................................................................ 3187
Installation........................................................................................................................ 3187
Axle Shaft.............................................................................................................................. 3188
Axle Shaft and Associated Parts..................................................................................................... 3188
Removal............................................................................................................................. 3188
Inspection and Repair............................................................................................................... 3189
Oil Seal Replacement................................................................................................................ 3190
Installation........................................................................................................................ 3190
Pinion Oil Seal......................................................................................................................... 3191
Pinion Oil Seal and Associated Parts................................................................................................ 3191
Removal............................................................................................................................. 3191
Inspection and Repair............................................................................................................... 3192
Installation........................................................................................................................ 3192
Differential Assembly................................................................................................................... 3193
Differential Assembly and Associated Parts.......................................................................................... 3193
Removal............................................................................................................................. 3193
Installation........................................................................................................................ 3194
Disassembled View................................................................................................................... 3195
Disassembly......................................................................................................................... 3196
Reassembly.......................................................................................................................... 3198
Differential Cage Assembly.............................................................................................................. 3205
Disassembled View................................................................................................................... 3205
Disassembly......................................................................................................................... 3206
Inspection and Repair............................................................................................................... 3206
Reassembly.......................................................................................................................... 3206
Locking Differential Assembly........................................................................................................... 3208
Disassembled View................................................................................................................... 3208
Disassembly......................................................................................................................... 3208
Inspection and Repair............................................................................................................... 3210
Reassembly.......................................................................................................................... 3210
Main Data and Specifications............................................................................................................ 3212
Special Tools........................................................................................................................... 3213
4B1 DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)............................................................................................ 3216
Service Precaution...................................................................................................................... 3216
Shift On The Fly System................................................................................................................. 3217
Outline of Shift on The Fly System.................................................................................................. 3217
Functions of Indicator Lamp............................................................................................................. 3221
Diagnosis............................................................................................................................... 3222
Front Axle Diagnosis.................................................................................................................... 3232
Shift On The Fly Vacuum Piping And Electric Equipment................................................................................... 3234
Vacuum piping diagram............................................................................................................... 3234
VSV Assembly, Actuator Assembly..................................................................................................... 3234
Vacuum Tank......................................................................................................................... 3234
Inspection And Repair............................................................................................................... 3235
4WD Control Unit........................................................................................................................ 3238
4WD Control Unit Associated Parts....................................................................................................... 3238
Removal................................................................................................................................. 3239
Installation............................................................................................................................ 3239
4B2 DRIVELINE CONTROL SYSTEM (TOD)......................................................................................................... 3240
Service Precaution...................................................................................................................... 3240
General Description..................................................................................................................... 3241
System Components....................................................................................................................... 3243
Parts Location...................................................................................................................... 3243
Functions of Indicator Lamp............................................................................................................. 3247
Diagnosis............................................................................................................................... 3251
Basic Diagnostic Flow Chart............................................................................................................. 3255
Parts Location.......................................................................................................................... 3256
Circuit Diagram......................................................................................................................... 3257
Connector List.......................................................................................................................... 3260
Checking Failed Pin..................................................................................................................... 3262
Checking Failed TOD Control Unit Pin.................................................................................................... 3265
Diagnostic Trouble Codes................................................................................................................ 3269
Fault Diagnosis from Trouble Codes...................................................................................................... 3270
Trouble Diagnosis Depending on The Status of TOD Indicator.............................................................................. 3297
Fault Diagnosis from Symptom............................................................................................................ 3324
4C DRIVE SHAFT SYSTEM..................................................................................................................... 3334
Service Precaution...................................................................................................................... 3334
General Description..................................................................................................................... 3334
Diagnosis............................................................................................................................... 3335
Front Hub and Disc...................................................................................................................... 3336
Disassembled View................................................................................................................... 3336
Disassembly......................................................................................................................... 3336
Inspection and Repair............................................................................................................... 3337
Reassembly.......................................................................................................................... 3338
Main Data and Specifications........................................................................................................ 3341
Special Tools....................................................................................................................... 3342
Front Drive Shaft Joint................................................................................................................. 3343
Front Drive Shaft Joints Replacement................................................................................................ 3343
Front Axle Drive Shaft.................................................................................................................. 3344
Front Axle Drive Shaft and Associated Parts......................................................................................... 3344
Disassembly......................................................................................................................... 3345
Inspection and Repair............................................................................................................... 3346
Bushing Replacement................................................................................................................. 3346
Reassembly.......................................................................................................................... 3347
Shift On The Fly System................................................................................................................. 3349
Shift On The Fly System and Associated Parts........................................................................................ 3349
Disassembly......................................................................................................................... 3349
Inspection and Repair............................................................................................................... 3351
Main Data and Specifications........................................................................................................ 3356
Special Tools....................................................................................................................... 3357
Front Propeller Shaft................................................................................................................... 3358
General Description................................................................................................................. 3358
Front Propeller Shaft and Associated Parts.......................................................................................... 3359
Removal............................................................................................................................. 3359
Installation........................................................................................................................ 3360
Disassembly (Except TOD 4ﾗ4)........................................................................................................ 3361
Universal Joint Disassembly......................................................................................................... 3362
Inspection and Repair............................................................................................................... 3363
Universal Joint Reassembly.......................................................................................................... 3366
Reassembly (Except TOD 4ﾗ4)......................................................................................................... 3367
Main Data and Specifications........................................................................................................ 3368
Rear Propeller Shaft.................................................................................................................... 3369
General Description................................................................................................................. 3369
Rear Propeller Shaft and Associated Parts........................................................................................... 3369
Removal............................................................................................................................. 3369
Installation........................................................................................................................ 3370
Disassembly......................................................................................................................... 3371
Universal Joint Disassembly......................................................................................................... 3372
Inspection and Repair............................................................................................................... 3373
Universal Joint Reassembly.......................................................................................................... 3374
Reassembly.......................................................................................................................... 3375
Main Data and Specifications........................................................................................................ 3376
4D1 TRANSFER CASE (STANDARD TYPE).......................................................................................................... 3377
Service Precaution...................................................................................................................... 3377
General Description..................................................................................................................... 3378
Transfer Rear Oil Seal.................................................................................................................. 3380
Removal............................................................................................................................. 3380
Installation........................................................................................................................ 3380
Transfer Case Assembly.................................................................................................................. 3381
Removal............................................................................................................................. 3381
Installation........................................................................................................................ 3381
Transfer Rear Case Assembly............................................................................................................. 3383
Removal............................................................................................................................. 3383
Installation........................................................................................................................ 3384
Disassembly......................................................................................................................... 3387
Inspection and Repair............................................................................................................... 3388
Reassembly.......................................................................................................................... 3388
Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)........................................................................... 3390
Disassembled View................................................................................................................... 3390
Disassembly......................................................................................................................... 3390
Inspection and Repair............................................................................................................... 3392
Reassembly.......................................................................................................................... 3392
Transfer Case Assembly.................................................................................................................. 3394
Disassembled View................................................................................................................... 3394
Disassembly......................................................................................................................... 3395
Inspection and Repair............................................................................................................... 3397
Reassembly.......................................................................................................................... 3401
Main Data and Specifications............................................................................................................ 3407
Special Tools........................................................................................................................... 3410
4D2 TRANSFER CASE (TOD).................................................................................................................... 3412
Service Precaution...................................................................................................................... 3412
Transfer Case Assembly.................................................................................................................. 3413
Removal............................................................................................................................. 3413
Installation........................................................................................................................ 3414
Transfer Rear Oil Seal.................................................................................................................. 3416
Transfer Rear Oil Seal and Associated Parts......................................................................................... 3416
Removal............................................................................................................................. 3416
Installation........................................................................................................................ 3416
TOD ECU................................................................................................................................. 3418
Removal............................................................................................................................. 3418
Installation........................................................................................................................ 3418
Unit Repair............................................................................................................................. 3419
Inspection.......................................................................................................................... 3419
Transfer Case........................................................................................................................... 3420
Disassembled View................................................................................................................... 3420
Disassembly......................................................................................................................... 3420
Reassembly.......................................................................................................................... 3421
Transfer Cover Assembly................................................................................................................. 3423
Disassembled View................................................................................................................... 3423
Disassembly......................................................................................................................... 3423
Reassembly.......................................................................................................................... 3425
Transfer Case Assembly Clutch Pack and Clutch Cam....................................................................................... 3427
Disassembled View................................................................................................................... 3427
Disassembly......................................................................................................................... 3427
Sprocket and Mechanical Lock............................................................................................................ 3429
Disassembled View................................................................................................................... 3429
Disassembly......................................................................................................................... 3429
Output Shafts and Shift Control Shaft................................................................................................... 3431
Disassembled View................................................................................................................... 3431
Disassembly......................................................................................................................... 3432
Transfer Case........................................................................................................................... 3434
Disassembled View................................................................................................................... 3434
Disassembly......................................................................................................................... 3435
Inspection and Repair............................................................................................................... 3437
Transfer Case........................................................................................................................... 3441
Disassembled View................................................................................................................... 3441
Reassembly.......................................................................................................................... 3441
Output Shafts and Shift Control Shaft................................................................................................... 3444
Disassembled View................................................................................................................... 3444
Reassembly.......................................................................................................................... 3444
Sprocket and Mechanical Lock............................................................................................................ 3447
Disassembled View................................................................................................................... 3447
Reassembly.......................................................................................................................... 3447
Clutch Pack and Clutch Cam.............................................................................................................. 3449
Disassembled View................................................................................................................... 3449
Reassembly.......................................................................................................................... 3449
Main Data and Specifications............................................................................................................ 3451
Special Tools........................................................................................................................... 3453
Sec.5 BRAKES.................................................................................................................................. 3454
5A BRAKE CONTROL SYSTEM................................................................................................................... 3454
Service Precaution...................................................................................................................... 3455
General Description..................................................................................................................... 3456
System Components................................................................................................................... 3456
Electronic Hydraulic Control Unit (EHCU)............................................................................................ 3456
ABS Warning Light................................................................................................................... 3457
Wheel Speed Sensor.................................................................................................................. 3457
G-Sensor............................................................................................................................ 3457
Normal and Anti-lock Braking........................................................................................................ 3457
Brake Pedal Travel.................................................................................................................. 3457
Acronyms and Abbreviations.......................................................................................................... 3457
General Diagnosis....................................................................................................................... 3458
General Information................................................................................................................. 3458
ABS Service Precautions............................................................................................................. 3458
Computer System Service Precautions................................................................................................. 3458
General Service Precautions......................................................................................................... 3458
Note on Intermittents............................................................................................................... 3458
Test Driving ABS Complaint Vehicles................................................................................................. 3458
"ABS" Warning Light................................................................................................................. 3459
Normal Operation.................................................................................................................... 3459
Basic Diagnostic Flow Chart......................................................................................................... 3459
Basic Inspection Procedure.......................................................................................................... 3460
Tech 2 Scan Tool.................................................................................................................... 3461
Getting Started..................................................................................................................... 3462
Operating Procedure................................................................................................................. 3462
Data List........................................................................................................................... 3464
EHCU Connector Pin-out Checks........................................................................................................... 3465
Circuit Diagram..................................................................................................................... 3466
Connector List...................................................................................................................... 3469
Part Location....................................................................................................................... 3471
Symptom Diagnosis....................................................................................................................... 3472
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate...................................................................... 3472
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................ 3473
Chart A-2 Uneven Braking Occurs While ABS Works..................................................................................... 3473
Chart A-3, TA-3 The Wheels Are Locked............................................................................................... 3474
Chart A-4 Brake Pedal Feed Is Abnormal.............................................................................................. 3474
Chart A-5,TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................. 3475
Diagnostic Trouble Codes................................................................................................................ 3476
Diagnosis By "ABS" Warning Light Illumination Pattern................................................................................... 3477
Diagnostic Trouble Codes (DTCs)..................................................................................................... 3477
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................ 3480
Chart B-2 EHCU Abnormality (DTC 14)................................................................................................. 3480
Chart B-3 Power Voltage Drop (DTC 15)............................................................................................... 3481
Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)........................................................................... 3481
Chart B-5 G-Sensor Circuit (DTC 21)................................................................................................. 3481
Chart B-6 Abnormal Transmission Input (DTC 23)...................................................................................... 3482
Chart B-7 Transfer Monitor (DTC 24)................................................................................................. 3483
Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32).......................................................................... 3483
Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35).......................................................................... 3484
Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41)......................................................................... 3484
Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42).............................................................................. 3484
Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43)......................................................................... 3485
Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44).............................................................................. 3485
Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45)....................................................................... 3485
Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)............................................................................ 3486
Chart B-16 FL Speed Sensor Disconnection (DTC 51)................................................................................... 3486
Chart B-17 FR Speed Sensor Disconnection (DTC 52)................................................................................... 3487
Chart B-18 RL Speed Sensor Disconnection (DTC 53)................................................................................... 3487
Chart B-19 RR Speed Sensor Disconnection (DTC 54)................................................................................... 3488
Chart B-20 FL Speed Sensor Short Circuit (DTC 61)................................................................................... 3489
Chart B-21 FR Speed Sensor Short Circuit (DTC 62)................................................................................... 3490
Chart B-22 RL Speed Sensor Short Circuit (DTC 63)................................................................................... 3491
Chart B-23 RR Speed Sensor Short Circuit (DTC 64)................................................................................... 3492
Chart B-24 Sensor Signal Input Abnormality (DTC 65)................................................................................. 3493
Unit Inspection Procedure............................................................................................................... 3494
Chart C-1-1 FL Sensor Output Inspection Procedure................................................................................... 3494
Chart C-1-2 FR Sensor Output Inspection Procedure................................................................................... 3495
Chart C-1-3 RL Sensor Output Inspection Procedure................................................................................... 3495
Chart C-1-4 RR Sensor Output Inspection Procedure................................................................................... 3496
Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2).......................................................................... 3496
Chart C-2 Transmission Input Inspection Procedure................................................................................... 3497
Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2)..................................................................... 3498
Special Tools........................................................................................................................... 3499
5B ANTI-LOCK BRAKE SYSTEM................................................................................................................. 3500
Service Precaution...................................................................................................................... 3500
Electronic Hydraulic Control Unit....................................................................................................... 3501
Electronic Hydraulic Control Unit and Associated Parts.............................................................................. 3501
Removal............................................................................................................................. 3501
Installation........................................................................................................................ 3501
G-Sensor................................................................................................................................ 3502
Removal............................................................................................................................. 3502
Inspection and Repair............................................................................................................... 3502
Installation........................................................................................................................ 3502
Front Wheel Speed Sensor................................................................................................................ 3503
Front Wheel Speed Sensor and Associated Parts....................................................................................... 3503
Removal............................................................................................................................. 3503
Inspection and Repair............................................................................................................... 3504
Installation........................................................................................................................ 3504
Rear Wheel Speed Sensor................................................................................................................. 3505
Rear Wheel Speed Sensor and Associated Parts........................................................................................ 3505
Removal............................................................................................................................. 3505
Inspection and Repair............................................................................................................... 3505
Installation........................................................................................................................ 3505
5C POWER-ASSISTED BRAKE SYSTEM............................................................................................................ 3506
Service Precaution...................................................................................................................... 3507
General Description..................................................................................................................... 3507
Diagnosis............................................................................................................................... 3510
General Diagnosis....................................................................................................................... 3511
Hydraulic Brakes........................................................................................................................ 3514
Filling Master Cylinder Reservoir................................................................................................... 3514
Deterioration of Brake Fluid........................................................................................................ 3514
Leakage of Brake Fluid.............................................................................................................. 3514
Bleeding Brake Hydraulic System..................................................................................................... 3514
Flushing Brake Hydraulic System..................................................................................................... 3515
Brake Pipes and Hoses............................................................................................................... 3515
Brake Hose Inspection............................................................................................................... 3515
Front / Rear Caliper Brake Hose......................................................................................................... 3516
Front / Rear Caliper Brake Hose and Associated Parts................................................................................ 3516
Removal............................................................................................................................. 3516
Installation........................................................................................................................ 3516
Rear Axle Brake Hose.................................................................................................................... 3517
Rear Axle Brake Hose and Associated Parts........................................................................................... 3517
Removal............................................................................................................................. 3517
Installation........................................................................................................................ 3517
Brake Pipe.............................................................................................................................. 3518
Removal............................................................................................................................. 3518
Installation........................................................................................................................ 3518
P & B (Proportioning and Bypass) Valve.................................................................................................. 3519
P & B (Proportioning and Bypass) Valve Sectional View............................................................................... 3519
Removal............................................................................................................................. 3519
Installation........................................................................................................................ 3519
Main Data and Specifications........................................................................................................ 3520
Brake Pedal............................................................................................................................. 3521
Checking Pedal Height............................................................................................................... 3521
Checking Pedal Travel............................................................................................................... 3521
Brake Pedal and Associated Parts.................................................................................................... 3522
Removal............................................................................................................................. 3522
Installation........................................................................................................................ 3522
Stoplight Switch........................................................................................................................ 3523
Removal............................................................................................................................. 3523
Installation........................................................................................................................ 3523
Main Data and Specifications........................................................................................................ 3524
Fluid Reservoir......................................................................................................................... 3525
Fluid Reservoir Tank and Associated Parts........................................................................................... 3525
Removal............................................................................................................................. 3525
Installation........................................................................................................................ 3525
Master Cylinder Assembly................................................................................................................ 3526
Master Cylinder Assembly and Associated Parts....................................................................................... 3526
Removal............................................................................................................................. 3526
Inspection and Repair............................................................................................................... 3526
Installation........................................................................................................................ 3527
Main Data and Specifications........................................................................................................ 3528
Special Tools....................................................................................................................... 3529
Vacuum Booster Assembly................................................................................................................. 3530
Vacuum Booster Assembly and Associated Parts........................................................................................ 3530
Removal............................................................................................................................. 3530
Inspection and Repair............................................................................................................... 3530
Installation........................................................................................................................ 3531
Exterior Components..................................................................................................................... 3533
Exterior Components and Associated Parts............................................................................................ 3533
Removal............................................................................................................................. 3533
Inspection and Repair............................................................................................................... 3534
Installation........................................................................................................................ 3534
Vacuum Booster Overhaul................................................................................................................. 3534
Vacuum Booster...................................................................................................................... 3534
Main Data and Specifications........................................................................................................ 3535
Special Tools....................................................................................................................... 3536
Front Disc Brake Pads................................................................................................................... 3537
Front Disc Brake Pads Inspection.................................................................................................... 3537
Front Disc Brake Pads and Associated Parts.......................................................................................... 3537
Removal............................................................................................................................. 3538
Installation........................................................................................................................ 3538
Front Disc Brake Rotor.................................................................................................................. 3540
Inspection.......................................................................................................................... 3540
Replacing Brake Rotors.............................................................................................................. 3540
Refinishing Brake Rotors............................................................................................................ 3540
Front Disc Brake Caliper Assembly....................................................................................................... 3542
Front Disc Brake Caliper Assembly and Associated Parts.............................................................................. 3542
Removal............................................................................................................................. 3542
Installation........................................................................................................................ 3543
Front Disc Brake Caliper................................................................................................................ 3545
Front Disc Brake Caliper Disassembled View.......................................................................................... 3545
Disassembly......................................................................................................................... 3545
Inspection and Repair............................................................................................................... 3546
Reassembly.......................................................................................................................... 3546
Main Data and Specifications........................................................................................................ 3548
Rear Disc Brake Pads.................................................................................................................... 3549
Brake Pads Inspection............................................................................................................... 3549
Brake Pads and Associated Parts..................................................................................................... 3549
Removal............................................................................................................................. 3550
Installation........................................................................................................................ 3550
Rear Disc Brake Rotor................................................................................................................... 3552
Inspection.......................................................................................................................... 3552
Replacing Brake Rotors.............................................................................................................. 3552
Refinishing Brake Rotors............................................................................................................ 3552
Rear Drum (In Disc) Inside Diameter Check........................................................................................... 3553
Rear Disc Brake Caliper Assembly........................................................................................................ 3554
Rear Disc Brake Caliper Assembly and Associated Parts............................................................................... 3554
Removal............................................................................................................................. 3554
Installation........................................................................................................................ 3555
Rear Disc Brake Caliper................................................................................................................. 3557
Rear Disc Brake Caliper Disassembled View........................................................................................... 3557
Disassembly......................................................................................................................... 3557
Inspection and Repair............................................................................................................... 3558
Reassembly.......................................................................................................................... 3558
Main Data and Specifications........................................................................................................ 3560
5D PARKING BRAKE SYSTEM................................................................................................................... 3561
Service Precaution...................................................................................................................... 3561
General Description..................................................................................................................... 3561
Operation............................................................................................................................... 3562
Parking Brake Lever and Front Cable..................................................................................................... 3563
Parking Brake Lever, Front Cable and Associated Parts............................................................................... 3563
Removal............................................................................................................................. 3563
Installation........................................................................................................................ 3564
Parking Brake Rear Cable................................................................................................................ 3565
Parking Brake Rear Cable and Associated Parts....................................................................................... 3565
Removal............................................................................................................................. 3565
Installation........................................................................................................................ 3566
Inspection and Repair............................................................................................................... 3567
Parking Brake Adjustment............................................................................................................ 3567
Main Data and Specifications............................................................................................................ 3568
Sec.6 ENGINE.................................................................................................................................. 3569
6A ENGINE MECHANICAL...................................................................................................................... 3569
Service Precaution...................................................................................................................... 3570
General Description..................................................................................................................... 3571
Engine Diagnosis........................................................................................................................ 3572
Cylinder Head Cover LH.................................................................................................................. 3586
Removal............................................................................................................................. 3586
Installation........................................................................................................................ 3587
Cylinder Head Cover RH.................................................................................................................. 3589
Removal............................................................................................................................. 3589
Installation........................................................................................................................ 3590
Common Chamber.......................................................................................................................... 3592
Removal............................................................................................................................. 3592
Installation........................................................................................................................ 3592
Exhaust Manifold LH..................................................................................................................... 3594
Removal............................................................................................................................. 3594
Installation........................................................................................................................ 3594
Exhaust Manifold RH..................................................................................................................... 3595
Removal............................................................................................................................. 3595
Installation........................................................................................................................ 3595
Crankshaft Pulley....................................................................................................................... 3596
Removal............................................................................................................................. 3596
Installation........................................................................................................................ 3596
Timing Belt............................................................................................................................. 3597
Removal............................................................................................................................. 3597
Installation........................................................................................................................ 3598
Camshaft................................................................................................................................ 3601
Removal............................................................................................................................. 3601
Installation........................................................................................................................ 3601
Cylinder Head........................................................................................................................... 3605
Removal............................................................................................................................. 3605
Installation........................................................................................................................ 3605
Valve Stem Oil Controller , Valve Spring and Valve Guide................................................................................ 3607
Removal............................................................................................................................. 3607
Installation........................................................................................................................ 3607
Piston, Piston Ring and Connecting Rod.................................................................................................. 3608
Removal............................................................................................................................. 3608
Installation........................................................................................................................ 3609
Crankshaft and Main Bearings............................................................................................................ 3610
Removal............................................................................................................................. 3610
Installation........................................................................................................................ 3611
Rear Oil Seal........................................................................................................................... 3615
Removal............................................................................................................................. 3615
Installation........................................................................................................................ 3615
Engine Assembly......................................................................................................................... 3616
Removal............................................................................................................................. 3616
Installation........................................................................................................................ 3616
Cylinder Head........................................................................................................................... 3620
Cylinder Head and Associated Parts.................................................................................................. 3620
Disassembly......................................................................................................................... 3620
Clean............................................................................................................................... 3621
Inspection and Repair............................................................................................................... 3621
Reassembly.......................................................................................................................... 3621
Valve Spring, Oil Controller, Valve, Valve Guide........................................................................................ 3624
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts............................................................... 3624
Disassembly......................................................................................................................... 3624
Inspection and Repair............................................................................................................... 3625
Reassembly.......................................................................................................................... 3628
Valve Clearance Adjustments......................................................................................................... 3629
Camshaft................................................................................................................................ 3631
Camshaft and Associated Parts....................................................................................................... 3631
Disassembly......................................................................................................................... 3631
Inspection and Repair............................................................................................................... 3632
Reassembly.......................................................................................................................... 3634
Crankshaft.............................................................................................................................. 3637
Crankshaft and Associated Parts..................................................................................................... 3637
Disassembly......................................................................................................................... 3637
Inspection and Repair............................................................................................................... 3638
Inspection and Repair............................................................................................................... 3639
Reassembly.......................................................................................................................... 3641
Piston and Connecting Rod............................................................................................................... 3645
Piston, Connecting Rod and Associate Parts.......................................................................................... 3645
Disassembly......................................................................................................................... 3645
Inspection and Repair............................................................................................................... 3646
Reassembly.......................................................................................................................... 3650
Cylinder Block.......................................................................................................................... 3653
Cylinder Block and Associated Parts................................................................................................. 3653
Disassembly......................................................................................................................... 3653
Inspection and Repair............................................................................................................... 3654
Reassembly.......................................................................................................................... 3655
Main Data and Specification............................................................................................................. 3658
Special Tool............................................................................................................................ 3664
6B ENGINE COOLING......................................................................................................................... 3666
Service Precaution...................................................................................................................... 3666
General Description..................................................................................................................... 3667
Diagnosis............................................................................................................................... 3670
Draining and Refilling Cooling System................................................................................................... 3671
Water Pump.............................................................................................................................. 3672
Water Pump and Associated Parts..................................................................................................... 3672
Removal............................................................................................................................. 3672
Inspection.......................................................................................................................... 3672
Installation........................................................................................................................ 3672
Thermostat.............................................................................................................................. 3673
Thermostat and Associated Parts..................................................................................................... 3673
Removal............................................................................................................................. 3673
Inspection.......................................................................................................................... 3673
Installation........................................................................................................................ 3673
Radiator................................................................................................................................ 3674
Radiator and Associated Parts....................................................................................................... 3674
Removal............................................................................................................................. 3674
Inspection.......................................................................................................................... 3675
Installation........................................................................................................................ 3676
Drive Belt and Cooling Fan.............................................................................................................. 3677
Drive Belt and Associated Parts..................................................................................................... 3677
Inspection.......................................................................................................................... 3677
Installation........................................................................................................................ 3677
Main Data and Specifications............................................................................................................ 3678
Special Tool............................................................................................................................ 3679
6C ENGINE FUEL............................................................................................................................ 3680
Service Precaution...................................................................................................................... 3680
General Description..................................................................................................................... 3681
Fuel Metering........................................................................................................................... 3682
Fuel Filter............................................................................................................................. 3683
Fuel Filter and Associated Parts.................................................................................................... 3683
Removal............................................................................................................................. 3683
Inspection.......................................................................................................................... 3683
Installation........................................................................................................................ 3683
Inspection.......................................................................................................................... 3684
In-Tank Fuel Filter................................................................................................................. 3684
Fuel Pump Flow Test................................................................................................................. 3684
Fuel Pump............................................................................................................................... 3685
Fuel Pump and Associated Parts...................................................................................................... 3685
Removal............................................................................................................................. 3685
Installation........................................................................................................................ 3685
Fuel Pump Relay......................................................................................................................... 3686
General Description................................................................................................................. 3686
Fuel Tank............................................................................................................................... 3686
Fuel Tank and Associated Parts...................................................................................................... 3686
Removal............................................................................................................................. 3686
Installation........................................................................................................................ 3687
Fuel Tube / Quick-Connect Fittings...................................................................................................... 3687
Precautions......................................................................................................................... 3687
Cautions During Work................................................................................................................ 3687
Removal............................................................................................................................. 3687
Reuse of Quick-Connector............................................................................................................ 3689
Assembling Advice................................................................................................................... 3689
Fuel Gauge Unit......................................................................................................................... 3690
Fuel Gauge Unit and Associated Parts................................................................................................ 3690
Removal............................................................................................................................. 3690
Installation........................................................................................................................ 3690
Fuel Filler Cap......................................................................................................................... 3691
General Description................................................................................................................. 3691
Inspection.......................................................................................................................... 3691
Main Data and Specifications............................................................................................................ 3691
6D1 ENGINE ELECTRICAL...................................................................................................................... 3692
Battery................................................................................................................................. 3692
General Description................................................................................................................. 3692
Diagnosis........................................................................................................................... 3692
Battery Charging.................................................................................................................... 3693
Jump Starting....................................................................................................................... 3693
Battery Removal..................................................................................................................... 3694
Battery Installation................................................................................................................ 3694
Main Data and Specifications........................................................................................................ 3695
6D2 IGNITION SYSTEM........................................................................................................................ 3696
Service Precaution...................................................................................................................... 3696
General Description..................................................................................................................... 3697
Diagnosis............................................................................................................................... 3697
Ignition Coil........................................................................................................................... 3698
Removal............................................................................................................................. 3698
Inspection and Repair............................................................................................................... 3698
Installation........................................................................................................................ 3698
Spark Plug.............................................................................................................................. 3699
Removal............................................................................................................................. 3699
Inspection and Repair............................................................................................................... 3699
Installation........................................................................................................................ 3699
Crankshaft Angle Sensor................................................................................................................. 3700
Removal............................................................................................................................. 3700
Installation........................................................................................................................ 3700
Main Data and Specifications............................................................................................................ 3701
6D3 STARTING AND CHARGING SYSTEM........................................................................................................... 3702
Service Precaution...................................................................................................................... 3702
Starting System......................................................................................................................... 3703
General Description..................................................................................................................... 3703
Diagnosis............................................................................................................................... 3705
Starter................................................................................................................................. 3706
Removal............................................................................................................................. 3706
Installation........................................................................................................................ 3706
Disassembled View................................................................................................................... 3707
Disassembly......................................................................................................................... 3708
Inspection and Repair............................................................................................................... 3710
Reassembly.......................................................................................................................... 3714
Main Data and Specifications........................................................................................................ 3716
Charging System......................................................................................................................... 3719
General Description..................................................................................................................... 3719
General On-Vehicle Inspection........................................................................................................... 3719
Generator............................................................................................................................... 3720
Removal............................................................................................................................. 3720
Inspection.......................................................................................................................... 3720
Installation........................................................................................................................ 3720
Disassembled View................................................................................................................... 3721
Disassembly......................................................................................................................... 3722
Inspection and Repair............................................................................................................... 3724
Reassembly.......................................................................................................................... 3726
Reassembly.......................................................................................................................... 3726
Main Data and Specifications........................................................................................................ 3727
6E 3.5L ENGINE DRIVEABILITY AND EMISSIONS................................................................................................. 3728
Specifications.......................................................................................................................... 3733
Tightening Specifications........................................................................................................... 3733
Diagrams and Schematics................................................................................................................. 3734
PCM Wiring Diagram (1 of 8)......................................................................................................... 3734
PCM Wiring Diagram (2 of 8)......................................................................................................... 3735
PCM Wiring Diagram (3 of 8)......................................................................................................... 3736
PCM Wiring Diagram (4 of 8)......................................................................................................... 3737
PCM Wiring Diagram (5 of 8, Automatic Transmission Only)............................................................................ 3738
PCM Wiring Diagram (6 of 8, Manual Transmission Only)............................................................................... 3739
PCM Wiring Diagram (7 of 8)......................................................................................................... 3740
PCM Wiring Diagram (8 of 8)......................................................................................................... 3741
PCM Pinouts............................................................................................................................. 3742
PCM Pinout Table, 32-Way Red Connector-Row "A"...................................................................................... 3742
PCM Pinout Table, 32-Way Red Connector-Row "B"...................................................................................... 3744
PCM Pinout Table, 32-Way White Connector-Row "C".................................................................................... 3745
PCM Pinout Table, 32-Way White Connector-Row "D".................................................................................... 3746
PCM Pinout Table, 32-Way Blue Connector-Row "E"..................................................................................... 3748
PCM Pinout Table, 32-Way Blue Connector-Row "F"..................................................................................... 3749
Component Locators...................................................................................................................... 3750
Engine Component Locator Table...................................................................................................... 3751
Undercarriage Component Locator..................................................................................................... 3752
Undercarriage Component Locator Table (Automatic Transmission)...................................................................... 3752
Undercarriage Component Locator Table (Manual Transmission)......................................................................... 3753
Fuse and Relay Panel (Underhood Electrical Center).................................................................................. 3753
Sensors and Miscellaneous Component Locators........................................................................................ 3754
Diagnosis............................................................................................................................... 3757
Strategy-Based Diagnostics.......................................................................................................... 3757
DTC Stored.......................................................................................................................... 3757
No DTC.............................................................................................................................. 3757
No Matching Symptom................................................................................................................. 3757
Intermittents....................................................................................................................... 3757
No Trouble Found.................................................................................................................... 3757
Verifying Vehicle Repair............................................................................................................ 3757
General Service Information............................................................................................................. 3758
OBD II Serviceablity Issues......................................................................................................... 3758
Emissions Control Information Label................................................................................................. 3758
Maintenance Schedule................................................................................................................ 3759
Visual / Physical Engine Compartment Inspection..................................................................................... 3759
Basic Knowledge of Tools Required................................................................................................... 3759
Serial Data Communications.............................................................................................................. 3759
Class II Serial Data Communications................................................................................................. 3759
On-Board Diagnostic (OBD II)............................................................................................................ 3759
On-Board Diagnostic Tests........................................................................................................... 3759
Comprehensive Component Monitor Diagnostic Operation................................................................................ 3759
System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations................................... 3760
Common OBD II Terms................................................................................................................. 3760
The Diagnostic Executive............................................................................................................ 3761
DTC Types........................................................................................................................... 3762
Decimal/Binary/Hexadecimal Conversions.............................................................................................. 3763
Verifying Vehicle Repair............................................................................................................ 3763
Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool......................................................................... 3763
Tech 2.............................................................................................................................. 3764
Tech 2 Features..................................................................................................................... 3765
Getting Started..................................................................................................................... 3765
Operating Procedure (For Example)................................................................................................... 3766
DTC Modes........................................................................................................................... 3767
DTC Information Mode................................................................................................................ 3767
Miscellaneous Test.................................................................................................................. 3768
Lamps Test.......................................................................................................................... 3768
Relays Test......................................................................................................................... 3769
EVAP Test........................................................................................................................... 3770
Idle Air Control System Test........................................................................................................ 3772
Fuel System Test.................................................................................................................... 3773
EGR Control Test.................................................................................................................... 3775
Variable Intake Manifold Solenoid Test.............................................................................................. 3775
Injector Balance Test............................................................................................................... 3776
Plottong Snapshot Graph................................................................................................................. 3777
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)...................................................... 3778
Flow Chart for Snapshot Replay (Plotting Graph)..................................................................................... 3779
Primary System-Based Diagnostic......................................................................................................... 3780
Fuel Control Heated Oxygen Sensor................................................................................................... 3780
HO2S Heater......................................................................................................................... 3780
Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation..................................................................... 3780
Evaporative Emission (EVAP) Purge System Vacuum Switch.............................................................................. 3781
Misfire Monitor Diagnostic Operation.................................................................................................... 3781
Misfire Counters.................................................................................................................... 3781
Fuel Trim System Monitor Diagnostic Operation........................................................................................... 3782
Fuel Trim Cell Diagnostic Weights................................................................................................... 3782
On-Board Diagnostic (OBD II) System Check............................................................................................... 3783
A/C Clutch Control Circuit Diagnosis.................................................................................................... 3786
Electronic Ignition System Diagnosis.................................................................................................... 3792
EVAP Canister Purge Solenoid and EVAP Vacuum Switch..................................................................................... 3792
Visual Check of The Evaporative Emission Canister....................................................................................... 3792
Fuel Metering System Check.............................................................................................................. 3792
Idle Air Control (IAC) Valve............................................................................................................ 3792
Fuel System Pressure Test............................................................................................................... 3792
Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure.............................................................. 3792
Knock Sensor Diagnosis.................................................................................................................. 3797
Powertrain Control Module (PCM) Diagnosis............................................................................................... 3797
Multiple PCM Information Sensor DTCS Set................................................................................................ 3797
Exhaust Gas Recirculation (EGR) Diagnosis............................................................................................... 3800
Engine Tech 2 Data Definitions and Ranges............................................................................................... 3800
Typical Scan Data Values................................................................................................................ 3803
No Malfunction Indicator Lamp (MIL)..................................................................................................... 3809
Malfunction Indicator Lamp (MIL) "ON" Steady............................................................................................ 3812
Engine Cranks But Will Not Run.......................................................................................................... 3814
Fuel System Electrical Test............................................................................................................. 3820
Fuel System Diagnosis................................................................................................................... 3823
Idle Air Control (IAC) System Check..................................................................................................... 3828
Knock Sensor (KS) System Check (Engine Knock, Poor Performance, or Poor Economy)........................................................ 3831
Exhaust Gas Recirculation (EGR) System Check............................................................................................ 3833
Manifold Absolute Pressure (MAP) Output Check........................................................................................... 3835
Evaporative (EVAP) Emissions Canister Purge Valve Check................................................................................. 3837
Upshift Lamp System Check (Manual Transmission Only).................................................................................... 3840
PCM Diagnostic Trouble Codes............................................................................................................ 3843
Diagnostic Trouble Code (DTC) P0101 MAF System Performance.............................................................................. 3847
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency.................................................................... 3850
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency................................................................... 3853
Diagnostic Trouble Code (DTC) P0106 MAP System Performance.............................................................................. 3856
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage...................................................................... 3859
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage..................................................................... 3862
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage...................................................................... 3865
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage..................................................................... 3868
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage...................................................................... 3871
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage..................................................................... 3874
Diagnostic Trouble Code (DTC) P0121 TP System Performance............................................................................... 3877
Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage....................................................................... 3880
Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage...................................................................... 3883
Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control...................................................... 3886
Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1............................................................ 3889
Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1........................................................... 3892
Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1.................................................................. 3895
Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Diagnostic Trouble Code (DTC) P0134 HO2S Circuit I........ 3899
Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1................................................................. 3902
Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2............................................................ 3905
Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2........................................................... 3908
Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2................................................... 3911
Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2................................................................. 3914
Diagnostic Trouble Code (DTC) P0143 HO2S Circuit Low Voltage Bank 1 Sensor 3............................................................ 3917
Diagnostic Trouble Code (DTC) P0144 HO2S Circuit High Voltage Bank 1 Sensor 3........................................................... 3920
Diagnostic Trouble Code (DTC) P0146 HO2S Circuit Insufficient Activity Bank 1 Sensor 3.................................................. 3923
Diagnostic Trouble Code (DTC) P0147 HO2S Heater Circuit Bank 1 Sensor 3................................................................. 3926
Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1............................................................ 3930
Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1........................................................... 3933
Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1.................................................................. 3936
Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1.................................................. 3940
Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Bank 2 Sensor................................................................... 3943
Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2............................................................ 3946
Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2........................................................... 3949
Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2.................................................. 3952
Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2................................................................. 3955
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1........................................................................ 3958
Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1........................................................................ 3962
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2........................................................................ 3966
Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2........................................................................ 3970
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit.......................................................................... 3974
Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit.......................................................................... 3977
Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit.......................................................................... 3980
Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit.......................................................................... 3983
Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit.......................................................................... 3986
Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit.......................................................................... 3989
Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected............................................................................. 3992
Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected........................................................................... 3996
Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected........................................................................... 3998
Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected........................................................................... 4000
Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected........................................................................... 4002
Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected........................................................................... 4004
Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected........................................................................... 4006
Diagnostic Trouble Code (DTC) P0325 KS Module Circuit................................................................................... 4008
Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit................................................................................... 4010
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit........................................................................ 4013
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency.................................................................... 4016
Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performance...................................................................... 4019
Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low.............................................................................. 4023
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit.......................................................................... 4027
Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit.......................................................................... 4030
Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit.......................................................................... 4033
Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit.......................................................................... 4036
Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit.......................................................................... 4039
Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit.......................................................................... 4042
Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient............................................................................... 4045
Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error.............................................................................. 4048
Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck...................................................................................... 4050
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage..................................................................................... 4052
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage.................................................................................... 4055
Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1 with Automatic Transmission........................................ 4058
Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1 with Manual Transmission........................................... 4061
Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2 with Automatic Transmission........................................ 4064
Diagnostic Trouble Code (DTC) P0440 EVAP System......................................................................................... 4066
Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected..................................................................... 4070
Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Blocked.......................................................................... 4074
Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor Low Voltage............................................................... 4077
Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor High Voltage.............................................................. 4080
Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit豊ow Voltage................................................................ 4083
Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit-High Voktage.............................................................. 4086
Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input............................................................................... 4088
Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM..................................................................... 4091
Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM.................................................................... 4094
Diagnostic Trouble Code (DTC) P0562 System Voltage Low.................................................................................. 4097
Diagnostic Trouble Code (DTC) P0563 System Voltage High................................................................................. 4099
Diagnostic Trouble Code (DTC) P0601 PCM Memory.......................................................................................... 4100
Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage........................................................ 4101
Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage................................................................ 4103
Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage........................................................ 4105
Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage......................................................... 4108
Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage......................................................... 4110
Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage........................................................ 4112
Diagnostic Trouble Code (DTC) P1121 TP Sensor Circuit Intermittent High Voltage......................................................... 4115
Diagnostic Trouble Code (DTC) P1122 TP Sensor Circuit Intermittent Low Voltage.......................................................... 4117
Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1......................................................... 4119
Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1.......................................................... 4123
Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1......................................................... 4127
Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1.................................................. 4131
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration................................................................ 4135
Diagnostic Trouble Code (DTC) P1380 ABS Rough Road ABS System Fault..................................................................... 4138
Diagnostic Trouble Code (DTC) P1381 ABS Rough Road Class 2 Serial Link Error............................................................ 4139
Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed.................................................................................... 4140
Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge................................................................... 4143
Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM.................................................................................. 4146
Diagnostic Trouble Code (DTC) P1509 IAC System High RPM................................................................................. 4149
Diagnostic Trouble Code (DTC) P1618 Serial Peripheral Interface (SPI) PCM Interprocessor Communication Error............................ 4152
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset................................................................................ 4153
Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM)................................................................. 4154
Diagnostic Trouble Code (DTC) P1650 Quad Driver Module "A" Fault........................................................................ 4157
Symptom Diagnosis....................................................................................................................... 4160
Default Matrix Table.................................................................................................................... 4188
On-Vehicle ServiceCamshaft Position (CMP) Sensor........................................................................................ 4191
Crankshaft Position (CKP) Sensor........................................................................................................ 4192
Engine Coolant Temperature (ECT) Sensor................................................................................................. 4192
Heated Oxygen Sensor (HO2S)............................................................................................................. 4193
Intake Air Temperature (IAT) Sensor..................................................................................................... 4196
Knock Sensor (KS)....................................................................................................................... 4197
Mass Air Flow (MAF) Sensor.............................................................................................................. 4198
Manifold Absolute Pressure (MAP) Sensor................................................................................................. 4198
Malfunction Indicator Lamp (MIL)........................................................................................................ 4199
Powertrain Control Module (PCM)......................................................................................................... 4199
EEPROM.................................................................................................................................. 4201
Throttle Position (TP) Sensor........................................................................................................... 4201
Vehicle Speed Sensor (VSS).............................................................................................................. 4202
Air Cleaner/Air Filter.................................................................................................................. 4203
Idle Air Control (IAC) Valve............................................................................................................ 4205
Common Chamber.......................................................................................................................... 4206
Accelerator Cable Assembly.............................................................................................................. 4206
Accelerator Pedal Replacement........................................................................................................... 4209
Fuel Filter Cap......................................................................................................................... 4211
Fuel Filter............................................................................................................................. 4211
Fuel Gauge Unit......................................................................................................................... 4214
Fuel Injectors.......................................................................................................................... 4215
Fuel Pressure Regulator................................................................................................................. 4216
Fuel Metering System.................................................................................................................... 4218
Fuel Pump Assembly...................................................................................................................... 4219
Fuel Pump Relay......................................................................................................................... 4219
Fuel Rail Assembly...................................................................................................................... 4220
Fuel Tank............................................................................................................................... 4221
Throttle Body (TB)...................................................................................................................... 4223
Electronic Ignition System.............................................................................................................. 4225
Catalytic Converter..................................................................................................................... 4226
Air Conditioning Relay.................................................................................................................. 4226
EVAP Canister Hoses..................................................................................................................... 4227
EVAP Canister........................................................................................................................... 4227
EVAP Canister Vent Solenoid............................................................................................................. 4228
Fuel Tank Pressure Sensor............................................................................................................... 4229
EVAP Canister Purge Solenoid............................................................................................................ 4229
Fuel Tank Vent Valve.................................................................................................................... 4230
Linear Exhaust Gas Recircula-tion (EGR) Valve........................................................................................... 4230
Positive Crankcase Ventilation (PCV) Valve.............................................................................................. 4231
Wiring and Connectors................................................................................................................... 4232
PCM Connectors and Terminals............................................................................................................ 4232
Wire Harness Repair: Twisted Shielded Cable............................................................................................. 4232
Twisted Leads........................................................................................................................... 4233
Weather-Pack Connector.................................................................................................................. 4234
Com-Pack III............................................................................................................................ 4235
Metri-Pack.............................................................................................................................. 4236
General Description (PCM and Sensors)................................................................................................... 4237
58X Reference PCM Input............................................................................................................. 4237
A/C Request Signal.................................................................................................................. 4237
Crankshaft Position (CKP) Sensor.................................................................................................... 4237
Camshaft Position (CMP) Sensor and Signal........................................................................................... 4237
Engine Coolant Temperature (ECT) Sensor............................................................................................. 4237
Electrically Erasable Programmable Read Only Memory (EEPROM)........................................................................ 4238
Fuel Control Heated Oxygen Sensors.................................................................................................. 4238
Catalyst Monitor Heated Oxygen Sensors.............................................................................................. 4238
Intake Air Temperature (IAT) Sensor................................................................................................. 4239
Knock Sensor........................................................................................................................ 4239
Linear Exhaust Gas Recirculation (EGR) Control...................................................................................... 4240
Mass Air Flow (MAF) Sensor.......................................................................................................... 4240
Manifold Absolute Pressure (MAP) Sensor............................................................................................. 4240
Powertrain Control Module (PCM)..................................................................................................... 4241
PCM Function........................................................................................................................ 4241
PCM Components...................................................................................................................... 4241
PCM Voltage Description............................................................................................................. 4241
PCM Input/Outputs................................................................................................................... 4242
PCM Service Precautions............................................................................................................. 4242
Reprogramming The PCM............................................................................................................... 4242
Throttle Position (TP) Sensor....................................................................................................... 4242
Transmission Fluid Temperature (TFT) Sensor......................................................................................... 4242
Transmission Range Switch........................................................................................................... 4243
Vehicle Speed Sensor (VSS).......................................................................................................... 4243
Use of Circuit Testing Tools........................................................................................................ 4243
Aftermarket Electrical and Vacuum Equipment......................................................................................... 4243
Electrostatic Discharge Damage...................................................................................................... 4243
Upshift Lamp........................................................................................................................ 4244
General Description (Air Induction)..................................................................................................... 4244
Air Induction System................................................................................................................ 4244
General Description (Fuel Metering)..................................................................................................... 4244
Acceleration Mode................................................................................................................... 4244
Accelerator Controls................................................................................................................ 4244
Battery Voltage Correction Mode..................................................................................................... 4244
CMP Signal.......................................................................................................................... 4244
Clear Flood Mode.................................................................................................................... 4244
Deceleration Mode................................................................................................................... 4244
Engine Speed/Vehicle Speed/Fuel Disable Mode........................................................................................ 4244
Fuel Cutoff Mode.................................................................................................................... 4244
Fuel Injector....................................................................................................................... 4244
Fuel Metering System Components..................................................................................................... 4245
Fuel Metering System Purpose........................................................................................................ 4245
Fuel Pressure Regulator............................................................................................................. 4245
Fuel Pump Electrical Circuit........................................................................................................ 4245
Fuel Rail........................................................................................................................... 4245
Idle Air Control (IAC) Valve........................................................................................................ 4246
Run Mode............................................................................................................................ 4246
Starting Mode....................................................................................................................... 4246
Throttle Body Unit.................................................................................................................. 4247
General Description (Electronic Ignition System)........................................................................................ 4247
Camshaft Position (CMP) Sensor...................................................................................................... 4247
Crankshaft Position (CKP) Sensor.................................................................................................... 4247
Electronic Ignition................................................................................................................. 4247
Ignition Coils...................................................................................................................... 4248
Ignition Control.................................................................................................................... 4248
Ignition Control PCM Output......................................................................................................... 4249
Knock Sensor (KS) PCM Input......................................................................................................... 4249
Powertrain Control Module (PCM)..................................................................................................... 4249
Spark Plug.......................................................................................................................... 4249
A/C Clutch Diagnosis.................................................................................................................... 4251
A/C Clutch Circuit Operation........................................................................................................ 4251
A/C Clutch Circuit Purpose.......................................................................................................... 4251
A/C Request Signal.................................................................................................................. 4251
General Description (Evaporative (EVAP) Emission System)................................................................................ 4251
EVAP Emission Control System Purpose................................................................................................ 4251
EVAP Emission Control System Operation.............................................................................................. 4252
Enhanced Evaporative Emission Control System........................................................................................ 4252
General Description (Exhaust Gas Recirculation (EGR) System)............................................................................ 4255
EGR Purpose......................................................................................................................... 4255
Linear EGR Valve.................................................................................................................... 4256
Linear EGR Control.................................................................................................................. 4256
Linear EGR Valve Operation and Results of Incorrect Operation....................................................................... 4256
EGR Pintle Position Sensor.......................................................................................................... 4256
General Description (Positive Crankcase Ventilation (PCV) System)....................................................................... 4256
Crankcase Ventilation System Purpose................................................................................................ 4256
Crankcase Ventilation System Operation.............................................................................................. 4256
Special Tools........................................................................................................................... 4258
6F ENGINE EXHAUST......................................................................................................................... 4260
General Description..................................................................................................................... 4261
Front Exhaust Pipe (Manual Transmission Only)........................................................................................... 4262
Front Exhaust Pipe and Associated Parts............................................................................................. 4262
Removal............................................................................................................................. 4262
Installation........................................................................................................................ 4262
Three Way Catalytic Converter LH (Automatic Transmission)............................................................................... 4263
Removal............................................................................................................................. 4263
Installation........................................................................................................................ 4263
Three Way Catalytic Converter RH........................................................................................................ 4264
Removal............................................................................................................................. 4264
Installation........................................................................................................................ 4264
Exhaust Silencer........................................................................................................................ 4265
Exhaust Silencer and Associated Parts............................................................................................... 4265
Removal............................................................................................................................. 4265
Installation........................................................................................................................ 4265
Rear Exhaust pipe....................................................................................................................... 4266
Rear Exhaust pipe and Associated Parts.............................................................................................. 4266
Removal............................................................................................................................. 4266
Installation........................................................................................................................ 4266
Main Data and Specifications............................................................................................................ 4267
6G ENGINE LUBRICATION..................................................................................................................... 4268
Service Precaution...................................................................................................................... 4268
General Description..................................................................................................................... 4269
Oil Pump................................................................................................................................ 4270
Oil Pump and Associated Parts....................................................................................................... 4270
Disassembly......................................................................................................................... 4270
Inspection and Repair............................................................................................................... 4271
Reassembly.......................................................................................................................... 4272
Oil Pan and Crankcase................................................................................................................... 4274
Removal............................................................................................................................. 4274
Installation........................................................................................................................ 4274
Oil Pump................................................................................................................................ 4277
Removal............................................................................................................................. 4277
Installation........................................................................................................................ 4277
Oil Pump Oil Seal....................................................................................................................... 4279
Removal............................................................................................................................. 4279
Installation........................................................................................................................ 4279
Oil Filter.............................................................................................................................. 4280
Removal............................................................................................................................. 4280
Installation........................................................................................................................ 4280
Main Data and Specification............................................................................................................. 4281
6H ENGINE SPEED CONTROL SYSTEM............................................................................................................ 4282
Service Precaution...................................................................................................................... 4282
Accelerator Pedal Control Cable......................................................................................................... 4283
Removal............................................................................................................................. 4283
Inspection.......................................................................................................................... 4283
Installation........................................................................................................................ 4283
Adjustment.......................................................................................................................... 4283
Accelerator Pedal....................................................................................................................... 4284
Accelerator Pedal and Associated Parts.............................................................................................. 4284
Removal............................................................................................................................. 4284
Installation........................................................................................................................ 4284
Adjustment.......................................................................................................................... 4284
6J INDUCTION.............................................................................................................................. 4285
Service Precaution...................................................................................................................... 4285
Air Cleaner Element..................................................................................................................... 4286
Removal............................................................................................................................. 4286
Inspection.......................................................................................................................... 4286
Installation........................................................................................................................ 4286
Sec.7 TRANSMISSION............................................................................................................................ 4287
7A AUTOMATIC TRANSMISSION (4L30-E)........................................................................................................ 4287
Service Precaution...................................................................................................................... 4289
Construction............................................................................................................................ 4289
Range Reference Chart................................................................................................................... 4290
Normal Operation Of 1999 4L30-E Transmission............................................................................................ 4291
Diagnosis............................................................................................................................... 4291
Driver Information...................................................................................................................... 4291
General Diagnosis Procedure............................................................................................................. 4294
Preliminary Inspection Chart............................................................................................................ 4295
Checking Transmission Fluid Level and Condition......................................................................................... 4296
Test Driving............................................................................................................................ 4297
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................ 4298
Mechanical / Hydraulic Diagnosis Symptoms Index......................................................................................... 4299
Stall Test.............................................................................................................................. 4309
Line Pressure Test...................................................................................................................... 4309
Shift Speed Chart....................................................................................................................... 4310
Lockup Speed Chart...................................................................................................................... 4312
Changing Transmission Fluid............................................................................................................. 4313
Selector Lever.......................................................................................................................... 4313
Inspection.......................................................................................................................... 4313
Removal............................................................................................................................. 4313
Installation........................................................................................................................ 4314
Mode Switch............................................................................................................................. 4315
Removal............................................................................................................................. 4315
Installation........................................................................................................................ 4315
Transmission (With Transfer Case)....................................................................................................... 4317
Transmission And Associated Parts................................................................................................... 4317
Removal............................................................................................................................. 4317
Installation........................................................................................................................ 4319
Solenoid (Main Case Valve Body)......................................................................................................... 4323
Removal............................................................................................................................. 4323
Installation........................................................................................................................ 4323
Solenoid (Adapter Case Valve Body)...................................................................................................... 4324
Removal............................................................................................................................. 4324
Installation........................................................................................................................ 4324
Valve Body Assembly (Main Case)......................................................................................................... 4325
Removal............................................................................................................................. 4325
Installation........................................................................................................................ 4325
Valve Body Assembly (Adapter Case)...................................................................................................... 4327
Removal............................................................................................................................. 4327
Installation........................................................................................................................ 4327
Powertrain Control Module (PCM)......................................................................................................... 4327
Removal............................................................................................................................. 4327
Installation........................................................................................................................ 4327
Speed Sensor (Extension Housing)........................................................................................................ 4328
Removal............................................................................................................................. 4328
Installation........................................................................................................................ 4328
Transmission Oil Temperature Sensor (Adapter Case)...................................................................................... 4328
Removal............................................................................................................................. 4328
Installation........................................................................................................................ 4329
Front Oil Seal (Converter Housing)...................................................................................................... 4329
Removal............................................................................................................................. 4329
Installation........................................................................................................................ 4329
Rear Oil Seal (Extension Housing)....................................................................................................... 4329
Removal............................................................................................................................. 4329
Installation........................................................................................................................ 4330
Transmission (4L30-E)................................................................................................................... 4330
Disassembly......................................................................................................................... 4330
Reassembly.......................................................................................................................... 4334
Converter Housing And Oil Pump Assembly................................................................................................. 4345
Disassembled View................................................................................................................... 4345
Disassembly......................................................................................................................... 4345
Inspection And Repair............................................................................................................... 4345
Reassembly.......................................................................................................................... 4345
Oil Pump................................................................................................................................ 4346
Disassembled View................................................................................................................... 4346
Disassembly......................................................................................................................... 4346
Inspection And Repair............................................................................................................... 4346
Reassembly.......................................................................................................................... 4346
Main Case Valve Body.................................................................................................................... 4347
Disassembled View................................................................................................................... 4347
Disassembly......................................................................................................................... 4347
Inspection And Repair............................................................................................................... 4348
Reassembly.......................................................................................................................... 4348
Adapter Case Valve Body................................................................................................................. 4349
Disassembled View................................................................................................................... 4349
Disassembly......................................................................................................................... 4349
Inspection And Repair............................................................................................................... 4349
Reassembly.......................................................................................................................... 4349
Third Clutch And Sprag Unit............................................................................................................. 4351
Disassembled View................................................................................................................... 4351
Disassembly......................................................................................................................... 4351
Inspection And Repair............................................................................................................... 4352
Reassembly.......................................................................................................................... 4352
Third Clutch............................................................................................................................ 4353
Disassembled View................................................................................................................... 4353
Disassemble......................................................................................................................... 4353
Inspection And Repair............................................................................................................... 4353
Reassembly.......................................................................................................................... 4353
Sprag Unit.............................................................................................................................. 4355
Disassembled View................................................................................................................... 4355
Disassembly......................................................................................................................... 4355
Inspection And Repair............................................................................................................... 4355
Reassembly.......................................................................................................................... 4355
Second Clutch........................................................................................................................... 4356
Disassembled View................................................................................................................... 4356
Disassembly......................................................................................................................... 4356
Inspection And Repair............................................................................................................... 4357
Reassembly.......................................................................................................................... 4357
3-4 Accumulator Piston.................................................................................................................. 4358
Disassembled View................................................................................................................... 4358
Disassembly......................................................................................................................... 4358
Inspection And Repair............................................................................................................... 4358
Reassembly.......................................................................................................................... 4359
Reverse Clutch Piston And Center Support................................................................................................ 4360
Disassembled View................................................................................................................... 4360
Disassembly......................................................................................................................... 4360
Inspection And Repair............................................................................................................... 4361
Reassembly.......................................................................................................................... 4361
Overrun Clutch And Turbine Shaft........................................................................................................ 4362
Disassembled View................................................................................................................... 4362
Disassembly......................................................................................................................... 4362
Inspection And Repair............................................................................................................... 4363
Reassembly.......................................................................................................................... 4363
Main Data And Specification............................................................................................................. 4365
Special Tools........................................................................................................................... 4369
4L30-E Parts List....................................................................................................................... 4372
7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)................................................................................................... 4380
Service Precaution...................................................................................................................... 4381
General Description..................................................................................................................... 4381
Electronic Control Diagram.......................................................................................................... 4382
Powertrain Control Module (PCM)..................................................................................................... 4383
Control System Diagram.............................................................................................................. 4384
Shift Control....................................................................................................................... 4385
Band Apply Control.................................................................................................................. 4385
Torque Converter Clutch Control..................................................................................................... 4385
Line Pressure Control............................................................................................................... 4385
On-Board Diagnostic System.......................................................................................................... 4385
Fail Safe Mechanism................................................................................................................. 4385
Torque Management Control........................................................................................................... 4385
ATF Warning Control................................................................................................................. 4385
ABS Control......................................................................................................................... 4385
Shift Mode Control.................................................................................................................. 4386
Gear Shift Control.................................................................................................................. 4387
Winter Drive Mode................................................................................................................... 4388
Backup Mode......................................................................................................................... 4388
Functions of Input / Output Components.............................................................................................. 4389
Diagnosis............................................................................................................................... 4390
Electronic Diagnosis................................................................................................................ 4390
How To Diagnose The Problem......................................................................................................... 4390
Check Trans Indicator............................................................................................................... 4390
Diagnostic Check.................................................................................................................... 4390
"Check Trans" Check................................................................................................................. 4391
Tech2 OBD II Connection............................................................................................................. 4392
F0: Transmission Data............................................................................................................... 4396
F1: PC Solenoid Data................................................................................................................ 4397
OBD II Diagnostic Management System................................................................................................. 4398
16-Terminal Data Link Connector (DLC)............................................................................................... 4399
Malfunction Indicator Lamp (MIL).................................................................................................... 4400
Types Of Diagnostic Trouble Codes (DTCs)............................................................................................ 4400
Clear DTC........................................................................................................................... 4400
DTC Check........................................................................................................................... 4401
PCM Precaution...................................................................................................................... 4401
Information On PCM.................................................................................................................. 4401
Intermittent Conditions............................................................................................................. 4401
Transmission And PCM Identification................................................................................................. 4402
Diagnostic Trouble Code (DTC) Identification........................................................................................ 4403
DTC P0218 Transmission Fluid Over Temperature........................................................................................... 4404
DTC P0560 System Voltage Malfunction.................................................................................................... 4406
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position...................................................................... 4409
DTC P0706 Transmission Range Switch (Mode Switch) Performance........................................................................... 4412
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Circuit Range/Performance......................................................... 4415
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input................................................................. 4418
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................ 4421
DTC P0719 TCC Brake Switch Circuit High (Stuck On)...................................................................................... 4424
DTC P0722 Transmission Output Speed Sensor (OSS) Low Input.............................................................................. 4427
DTC P0723 Transmission Output Speed Sensor (OSS) Intermittent........................................................................... 4430
DTC P0724 TCC Brake Switch Circuit Low (Stuck Off)...................................................................................... 4433
DTC P0730 Transmission Incorrect Gear Ratio............................................................................................. 4435
DTC P0742 Torque Converter Clutch (TCC) Circuit Stuck On................................................................................ 4438
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical.............................................................. 4440
DTC P0751 Shift Solenoid A Performance Without Input Speed.............................................................................. 4442
DTC P0753 Shift Solenoid A Electrical................................................................................................... 4444
DTC P0756 Shift Solenoid B Performance Without Input Speed.............................................................................. 4447
DTC P0758 Shift Solenoid B Electrical................................................................................................... 4449
DTC P1790 ROM Transmission Side Bad Check Sum........................................................................................... 4453
DTC P1792 EEPROM Transmission Side Bad Check Sum........................................................................................ 4454
DTC P1835 Kickdown Switch Always On..................................................................................................... 4455
DTC P1850 Brake Band Apply Solenoid Malfunction......................................................................................... 4457
DTC P1860 TCC Solenoid Electrical....................................................................................................... 4461
DTC P1870 Transmission Component Slipping............................................................................................... 4464
7B MANUAL TRANSMISSION.................................................................................................................... 4466
Service Precaution...................................................................................................................... 4466
General Description..................................................................................................................... 4467
Diagnosis............................................................................................................................... 4468
Manual Transmission Assembly............................................................................................................ 4469
Removal............................................................................................................................. 4469
Installation........................................................................................................................ 4473
Disassembled View................................................................................................................... 4478
Disassembly......................................................................................................................... 4481
Main Data and Specifications............................................................................................................ 4527
Special Tools........................................................................................................................... 4529
7C CLUTCH................................................................................................................................. 4531
Service Precaution...................................................................................................................... 4531
General Description..................................................................................................................... 4532
Diagnosis............................................................................................................................... 4536
Clutch Assembly......................................................................................................................... 4537
Clutch Assembly and Associated Parts................................................................................................ 4537
Removal............................................................................................................................. 4537
Inspection and Repair............................................................................................................... 4538
Installation........................................................................................................................ 4542
Clutch Control.......................................................................................................................... 4545
Clutch Control Parts................................................................................................................ 4545
Removal............................................................................................................................. 4545
Inspection and Repair............................................................................................................... 4545
Installation........................................................................................................................ 4546
Adjustment.......................................................................................................................... 4546
Master Cylinder......................................................................................................................... 4549
Inspection and Repair............................................................................................................... 4549
Slave Cylinder.......................................................................................................................... 4550
Disassembled View................................................................................................................... 4550
Disassembly......................................................................................................................... 4550
Inspection and Repair............................................................................................................... 4550
Reassembly.......................................................................................................................... 4551
Main Data and Specifications............................................................................................................ 4552
Special Tools........................................................................................................................... 4554
Sec.8 BODY AND ACCESSORIES.................................................................................................................... 4555
8A LIGHTING SYSTEM........................................................................................................................ 4555
Service Precaution...................................................................................................................... 4556
Headlight Bulb.......................................................................................................................... 4556
Removal............................................................................................................................. 4556
Installation........................................................................................................................ 4556
Headlight............................................................................................................................... 4557
Headlight and Associated Parts...................................................................................................... 4557
Removal............................................................................................................................. 4557
Installation........................................................................................................................ 4557
Headlight Adjustment................................................................................................................ 4557
Fog Light Bulb.......................................................................................................................... 4558
Removal............................................................................................................................. 4558
Installation........................................................................................................................ 4558
Fog Light Assembly...................................................................................................................... 4559
Removal............................................................................................................................. 4559
Installation........................................................................................................................ 4559
Fog Light Adjustment................................................................................................................ 4559
Front Side Marker Light Bulb............................................................................................................ 4559
Removal............................................................................................................................. 4559
Installation........................................................................................................................ 4559
Parking Light Bulb...................................................................................................................... 4560
Removal and Installation............................................................................................................ 4560
Taillight Bulb.......................................................................................................................... 4560
Removal............................................................................................................................. 4560
Installation........................................................................................................................ 4560
License Plate Light Bulb................................................................................................................ 4561
Removal............................................................................................................................. 4561
Installation........................................................................................................................ 4561
Stoplight Bulb.......................................................................................................................... 4561
Removal and Installation............................................................................................................ 4561
High Mount Stoplight.................................................................................................................... 4561
Removal............................................................................................................................. 4561
Installation........................................................................................................................ 4562
Front Turn Signal Light Bulb............................................................................................................ 4562
Removal............................................................................................................................. 4562
Installation........................................................................................................................ 4562
Rear Turn Signal Light Bulb............................................................................................................. 4563
Removal............................................................................................................................. 4563
Installation........................................................................................................................ 4563
Cornering Light Bulb.................................................................................................................... 4563
Removal............................................................................................................................. 4563
Installation........................................................................................................................ 4563
Backup Light Bulb....................................................................................................................... 4564
Removal............................................................................................................................. 4564
Installation........................................................................................................................ 4564
Dome Light Bulb......................................................................................................................... 4564
Removal............................................................................................................................. 4564
Installation........................................................................................................................ 4564
Luggage Room Light Bulb................................................................................................................. 4565
Removal............................................................................................................................. 4565
Installation........................................................................................................................ 4565
Courtesy Light Bulb..................................................................................................................... 4565
Removal............................................................................................................................. 4565
Installation........................................................................................................................ 4565
Map Light Switch/Bulb................................................................................................................... 4566
Removal............................................................................................................................. 4566
Installation........................................................................................................................ 4566
Cigarette Lighter Illumination Bulb..................................................................................................... 4566
Removal............................................................................................................................. 4566
Installation........................................................................................................................ 4566
Ashtray Illumination Bulb............................................................................................................... 4567
Removal............................................................................................................................. 4567
Installation........................................................................................................................ 4567
Glove Box Illumination Bulb............................................................................................................. 4567
Removal............................................................................................................................. 4567
Installation........................................................................................................................ 4567
Vanity Mirror Illumination Bulb......................................................................................................... 4568
Removal............................................................................................................................. 4568
Installation........................................................................................................................ 4568
Starter Switch.......................................................................................................................... 4568
Removal............................................................................................................................. 4568
Installation........................................................................................................................ 4569
Lighting Switch (Combination Switch).................................................................................................... 4569
Removal............................................................................................................................. 4569
Installation........................................................................................................................ 4570
Fog Light Switch........................................................................................................................ 4570
Removal............................................................................................................................. 4570
Installation........................................................................................................................ 4571
Stoplight Switch (W/O Cruise Control)................................................................................................... 4571
Removal............................................................................................................................. 4571
Installation........................................................................................................................ 4571
Brake Switch (W/Cruise Control)......................................................................................................... 4572
Removal............................................................................................................................. 4572
Installation........................................................................................................................ 4572
Turn Signal Switch/Cornering Light Switch (Combination Switch).......................................................................... 4572
Removal and Installation............................................................................................................ 4572
Hazard Warning Switch................................................................................................................... 4572
Removal............................................................................................................................. 4572
Installation........................................................................................................................ 4573
Tailgate Switch......................................................................................................................... 4573
Removal............................................................................................................................. 4573
Installation........................................................................................................................ 4573
Door Switch............................................................................................................................. 4574
Removal............................................................................................................................. 4574
Installation........................................................................................................................ 4574
Rear Defogger Switch.................................................................................................................... 4574
Removal............................................................................................................................. 4574
Installation........................................................................................................................ 4575
Seat Heater Switch...................................................................................................................... 4575
Removal............................................................................................................................. 4575
Installation........................................................................................................................ 4575
Key Remind Switch (Starter Switch)...................................................................................................... 4575
Removal and Installation............................................................................................................ 4575
Illumination Controller................................................................................................................. 4576
Removal............................................................................................................................. 4576
Installation........................................................................................................................ 4576
Main Data and Specifications............................................................................................................ 4577
8B WIPER / WASHER SYSTEM.................................................................................................................. 4579
Service Precaution...................................................................................................................... 4579
Windshield Wiper/Washer System.......................................................................................................... 4580
General Description................................................................................................................. 4580
Windshield Wiper And Washer Switch...................................................................................................... 4580
Removal and Installation............................................................................................................ 4580
Windshield Wiper Motor.................................................................................................................. 4580
Removal............................................................................................................................. 4580
Installation........................................................................................................................ 4580
Windshield Washer Motor................................................................................................................. 4581
Removal............................................................................................................................. 4581
Installation........................................................................................................................ 4581
Windshield Wiper Linkage................................................................................................................ 4582
Windshield Wiper Linkage and Associated Parts....................................................................................... 4582
Removal............................................................................................................................. 4582
Installation........................................................................................................................ 4582
Windshield Wiper Arm/Blade.............................................................................................................. 4583
Removal............................................................................................................................. 4583
Installation........................................................................................................................ 4583
Windshield Wiper Blade Rubber........................................................................................................... 4584
Removal............................................................................................................................. 4584
Installation........................................................................................................................ 4584
Rear Wiper/Washer System................................................................................................................ 4585
General Description................................................................................................................. 4585
Rear Wiper and Washer Switch............................................................................................................ 4585
Removal............................................................................................................................. 4585
Installation........................................................................................................................ 4585
Rear Wiper Motor........................................................................................................................ 4586
Removal............................................................................................................................. 4586
Installation........................................................................................................................ 4586
Alarm & Relay Control Unit.............................................................................................................. 4587
Removal............................................................................................................................. 4587
Installation........................................................................................................................ 4587
Rear Washer Motor....................................................................................................................... 4587
Removal............................................................................................................................. 4587
Installation........................................................................................................................ 4587
Rear Wiper Arm/Blade.................................................................................................................... 4588
Removal............................................................................................................................. 4588
Installation........................................................................................................................ 4588
Rear Washer Nozzle...................................................................................................................... 4588
Removal............................................................................................................................. 4588
Installation........................................................................................................................ 4588
Rear Washer Nozzle Angle Adjustment................................................................................................. 4588
Rear Wiper Blade Rubber................................................................................................................. 4589
Removal and Installation............................................................................................................ 4589
Main Data and Specifications............................................................................................................ 4589
8C ENTERTAINMENT.......................................................................................................................... 4590
Service Precaution...................................................................................................................... 4590
Cigarette Lighter....................................................................................................................... 4591
General Description................................................................................................................. 4591
Removal............................................................................................................................. 4591
Installation........................................................................................................................ 4591
Digital Clock........................................................................................................................... 4591
Removal............................................................................................................................. 4591
Installation........................................................................................................................ 4592
Rod Type Antenna........................................................................................................................ 4592
Removal............................................................................................................................. 4592
Installation........................................................................................................................ 4592
Diversity Glass Antenna................................................................................................................. 4593
Glass Antenna System Parts Location................................................................................................. 4593
Glass Antenna Pattern............................................................................................................... 4594
Glass Antenna Amplifier Removal..................................................................................................... 4594
Glass Antenna Amplifier Installation................................................................................................ 4594
Radio................................................................................................................................... 4595
Removal............................................................................................................................. 4595
Installation........................................................................................................................ 4595
Front Speaker........................................................................................................................... 4596
Removal............................................................................................................................. 4596
Installation........................................................................................................................ 4596
Tweeter Assembly........................................................................................................................ 4596
Removal............................................................................................................................. 4596
Installation........................................................................................................................ 4596
Rear Speaker............................................................................................................................ 4597
Removal............................................................................................................................. 4597
Installation........................................................................................................................ 4597
8D WIRING SYSTEM.......................................................................................................................... 4598
Service Precaution...................................................................................................................... 4599
General Description..................................................................................................................... 4600
Notes for Working on Electrical Items............................................................................................... 4600
Symbols and Abbreviations........................................................................................................... 4606
Parts for Electrical Circuit........................................................................................................ 4610
Reading the Circuit Diagram......................................................................................................... 4619
Main Data and Specifications............................................................................................................ 4622
Fuse, Fusible Link and Circuit Breaker Location..................................................................................... 4622
Relay and Fuse Box.................................................................................................................. 4623
Fuse Box............................................................................................................................ 4623
Reference Table of Fuse, Fusible Link and Circuit Breaker........................................................................... 4624
Relay Location...................................................................................................................... 4627
Diode Location...................................................................................................................... 4629
Grounding Point..................................................................................................................... 4631
Cable Harness Routing............................................................................................................... 4637
Fuse Block Circuit...................................................................................................................... 4641
Circuit Diagram..................................................................................................................... 4641
Parts Location...................................................................................................................... 4645
Start and Charging...................................................................................................................... 4646
General Description................................................................................................................. 4646
Circuit Diagram..................................................................................................................... 4647
Parts Location...................................................................................................................... 4649
Powertrain Control Module (PCM)......................................................................................................... 4650
General Description................................................................................................................. 4650
Circuit Diagram..................................................................................................................... 4651
Parts Location...................................................................................................................... 4663
Headlight and Fog Light................................................................................................................. 4666
General Description................................................................................................................. 4666
Circuit Diagram..................................................................................................................... 4667
Parts Location...................................................................................................................... 4669
Diagnosis........................................................................................................................... 4670
Front Side Marker Light, Parking Light, Taillight and License Plate Light............................................................... 4678
General Description................................................................................................................. 4678
Circuit Diagram..................................................................................................................... 4679
Parts Location...................................................................................................................... 4681
Diagnosis........................................................................................................................... 4682
Interior Illumination Light............................................................................................................. 4687
General Description................................................................................................................. 4687
Circuit Diagram..................................................................................................................... 4688
Parts Location...................................................................................................................... 4692
Diagnosis........................................................................................................................... 4693
Turn Signal Light, Hazard Warning Light and Cornering Light............................................................................. 4694
General Description................................................................................................................. 4694
Circuit Diagram..................................................................................................................... 4695
Parts Location...................................................................................................................... 4698
Diagnosis........................................................................................................................... 4699
Stoplight............................................................................................................................... 4705
General Description................................................................................................................. 4705
Circuit Diagram..................................................................................................................... 4706
Parts Location...................................................................................................................... 4707
Diagnosis........................................................................................................................... 4708
Backup Light............................................................................................................................ 4711
General Description................................................................................................................. 4711
Circuit Diagram..................................................................................................................... 4712
Parts Location...................................................................................................................... 4713
Diagnosis........................................................................................................................... 4714
Horn.................................................................................................................................... 4717
General Description................................................................................................................. 4717
Circuit Diagram..................................................................................................................... 4718
Parts Location...................................................................................................................... 4719
Diagnosis........................................................................................................................... 4720
Dome Light, Luggage Room Light, Courtesy Light, Map Light, Seat Belt Switch and Warning Buzzer.......................................... 4722
General Description................................................................................................................. 4722
Circuit Diagram..................................................................................................................... 4723
Parts Location...................................................................................................................... 4725
Diagnosis........................................................................................................................... 4726
Power Door Lock......................................................................................................................... 4727
General Description................................................................................................................. 4727
Circuit Diagram..................................................................................................................... 4728
Parts Location...................................................................................................................... 4732
Diagnosis........................................................................................................................... 4733
Power Window............................................................................................................................ 4737
General Description................................................................................................................. 4737
Circuit Diagram..................................................................................................................... 4738
Parts Location...................................................................................................................... 4739
Diagnosis........................................................................................................................... 4740
Cruise Control.......................................................................................................................... 4746
General Description................................................................................................................. 4746
Circuit Diagram..................................................................................................................... 4747
Parts Location...................................................................................................................... 4749
Diagnosis........................................................................................................................... 4750
Anti-Lock Brake System (ABS)............................................................................................................ 4756
General Description................................................................................................................. 4756
Circuit Diagram..................................................................................................................... 4757
Parts Location...................................................................................................................... 4760
A/T Shift Lock.......................................................................................................................... 4761
General Description................................................................................................................. 4761
Circuit Diagram..................................................................................................................... 4762
Parts Location...................................................................................................................... 4763
Windshield Wiper and Washer............................................................................................................. 4764
General Description................................................................................................................. 4764
Circuit Diagram..................................................................................................................... 4765
Parts Location...................................................................................................................... 4766
Diagnosis........................................................................................................................... 4767
Rear Wiper/Washer....................................................................................................................... 4775
General Description................................................................................................................. 4775
Circuit Diagram..................................................................................................................... 4776
Parts Location...................................................................................................................... 4778
Diagnosis........................................................................................................................... 4779
Rear Defogger........................................................................................................................... 4786
General Description................................................................................................................. 4786
Circuit Diagram..................................................................................................................... 4787
Parts Location...................................................................................................................... 4788
Diagnosis........................................................................................................................... 4789
Audio................................................................................................................................... 4792
General Description................................................................................................................. 4792
Circuit Diagram..................................................................................................................... 4793
Parts Location...................................................................................................................... 4795
Cigarette Lighter and Digital........................................................................................................... 4796
General Description................................................................................................................. 4796
Circuit Diagram..................................................................................................................... 4797
Parts Location...................................................................................................................... 4798
Diagnosis........................................................................................................................... 4799
Power Door Mirror....................................................................................................................... 4801
General Description................................................................................................................. 4801
Circuit Diagram..................................................................................................................... 4802
Parts Location...................................................................................................................... 4805
Diagnosis........................................................................................................................... 4806
Anti-Theft System with Keyless Entry.................................................................................................... 4814
Circuit Diagram..................................................................................................................... 4814
Parts Location...................................................................................................................... 4819
Diagnosis........................................................................................................................... 4821
Meter and Warning/Indicator Light....................................................................................................... 4827
General Description................................................................................................................. 4827
Circuit Diagram..................................................................................................................... 4828
Parts Location...................................................................................................................... 4839
Diagnosis........................................................................................................................... 4840
A/T Shift Indicator..................................................................................................................... 4852
General Description................................................................................................................. 4852
Circuit Diagram..................................................................................................................... 4853
Parts Location...................................................................................................................... 4855
Heater and Air Conditioning............................................................................................................. 4856
General Description................................................................................................................. 4856
Circuit Diagram..................................................................................................................... 4857
Parts Location...................................................................................................................... 4860
Sun Roof................................................................................................................................ 4861
General Description................................................................................................................. 4861
Circuit Diagram..................................................................................................................... 4862
Parts Location...................................................................................................................... 4863
Diagnosis........................................................................................................................... 4864
Power Seat.............................................................................................................................. 4867
General Description................................................................................................................. 4867
Circuit Diagram..................................................................................................................... 4868
Parts Location...................................................................................................................... 4870
Diagnosis........................................................................................................................... 4871
Seat Heater............................................................................................................................. 4879
General Description................................................................................................................. 4879
Circuit Diagram..................................................................................................................... 4880
Parts Location...................................................................................................................... 4881
Diagnosis........................................................................................................................... 4882
Supplemental Restraint System (SRS)-Air Bag............................................................................................. 4884
General Description................................................................................................................. 4884
Circuit Diagram..................................................................................................................... 4885
Parts Location...................................................................................................................... 4886
Shift on the Fly System................................................................................................................. 4887
Circuit Diagram..................................................................................................................... 4887
Parts Location...................................................................................................................... 4889
Torque on Demand (T.O.D.)............................................................................................................... 4890
Circuit Diagram..................................................................................................................... 4890
Parts Location...................................................................................................................... 4893
Harness Connector Faces................................................................................................................. 4894
8E METER AND GAUGE........................................................................................................................ 4916
Service Precaution...................................................................................................................... 4916
General Description..................................................................................................................... 4916
Meter Assembly.......................................................................................................................... 4917
General Description................................................................................................................. 4917
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights.................................................. 4917
Table for Meter/Gauge Connector Terminal Connections................................................................................ 4921
Removal............................................................................................................................. 4925
Installation........................................................................................................................ 4925
Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb, A/T Indicator Light Bulb............................................. 4925
Removal............................................................................................................................. 4925
Installation........................................................................................................................ 4925
Vehicle Speed Sensor.................................................................................................................... 4926
Removal............................................................................................................................. 4926
Installation........................................................................................................................ 4926
Fuel Tank Unit.......................................................................................................................... 4926
Removal............................................................................................................................. 4926
Installation........................................................................................................................ 4926
Multi Meter............................................................................................................................. 4927
Removal............................................................................................................................. 4927
Installation........................................................................................................................ 4927
Ambient Sensor.......................................................................................................................... 4927
Removal............................................................................................................................. 4927
Installation........................................................................................................................ 4927
Main Data and Specifications............................................................................................................ 4928
8F BODY STRUCTURE......................................................................................................................... 4929
Service Precaution...................................................................................................................... 4931
Frame................................................................................................................................... 4931
General Description................................................................................................................. 4931
Frame Dimensions.................................................................................................................... 4932
General Description................................................................................................................. 4933
Front Bumper............................................................................................................................ 4933
Parts Location...................................................................................................................... 4933
Removal............................................................................................................................. 4934
Installation........................................................................................................................ 4934
Front Bumper Slider Bracket............................................................................................................. 4934
Removal............................................................................................................................. 4934
Installation........................................................................................................................ 4934
Rear Bumper............................................................................................................................. 4935
Parts Location...................................................................................................................... 4935
Removal............................................................................................................................. 4935
Installation........................................................................................................................ 4936
Rear Bumper Slider...................................................................................................................... 4937
Removal............................................................................................................................. 4937
Installation........................................................................................................................ 4937
General Description................................................................................................................. 4938
Cowl Cover.............................................................................................................................. 4938
Parts Location...................................................................................................................... 4938
Removal............................................................................................................................. 4938
Installation........................................................................................................................ 4939
Engine Hood............................................................................................................................. 4939
Removal............................................................................................................................. 4939
Installation........................................................................................................................ 4939
Engine Hood Hinge....................................................................................................................... 4940
Parts Location...................................................................................................................... 4940
Removal............................................................................................................................. 4940
Installation........................................................................................................................ 4940
Engine Hood Lock........................................................................................................................ 4941
Parts Location...................................................................................................................... 4941
Removal............................................................................................................................. 4941
Installation........................................................................................................................ 4942
Radiator Grille And Front End Lower Panel............................................................................................... 4942
Parts Location...................................................................................................................... 4942
Removal............................................................................................................................. 4942
Installation........................................................................................................................ 4943
Front Fender Panel...................................................................................................................... 4944
Parts Location...................................................................................................................... 4944
Removal............................................................................................................................. 4944
Installation........................................................................................................................ 4945
Body Mounting........................................................................................................................... 4946
Parts Location...................................................................................................................... 4946
Removal (No.1-No. 2)................................................................................................................ 4946
Removal (No. 3-No. 6)............................................................................................................... 4947
Installation........................................................................................................................ 4948
General Description..................................................................................................................... 4949
Body Dimension.......................................................................................................................... 4950
Instrument Panel Assembly............................................................................................................... 4968
Parts Location...................................................................................................................... 4968
Removal............................................................................................................................. 4968
Installation........................................................................................................................ 4973
Cross Beam Assembly..................................................................................................................... 4974
Parts Location...................................................................................................................... 4974
Removal............................................................................................................................. 4974
Installation........................................................................................................................ 4975
Front Door Assembly..................................................................................................................... 4976
Parts Location...................................................................................................................... 4976
Removal............................................................................................................................. 4976
Installation........................................................................................................................ 4976
Rear Door Assembly...................................................................................................................... 4977
Parts Location...................................................................................................................... 4977
Removal............................................................................................................................. 4977
Installation........................................................................................................................ 4978
Door Strikers........................................................................................................................... 4978
Adjustment.......................................................................................................................... 4978
Door Check Arm Assembly (Front & Rear).................................................................................................. 4979
Parts Location...................................................................................................................... 4979
Removal............................................................................................................................. 4979
Installation........................................................................................................................ 4980
Front Window Regulator, Glass And Glass Run............................................................................................. 4980
Parts Location...................................................................................................................... 4980
Removal............................................................................................................................. 4980
Installation........................................................................................................................ 4982
Rear Window Regulator And Glass......................................................................................................... 4983
Parts Location...................................................................................................................... 4983
Removal............................................................................................................................. 4983
Installation........................................................................................................................ 4984
Rear Door Fixed Glass And Glass Run..................................................................................................... 4985
Parts Location...................................................................................................................... 4985
Removal............................................................................................................................. 4985
Installation........................................................................................................................ 4986
Front Door Sash Moulding................................................................................................................ 4987
Parts Location...................................................................................................................... 4987
Removal............................................................................................................................. 4987
Installation........................................................................................................................ 4987
Rear Door Moulding...................................................................................................................... 4988
Parts Location...................................................................................................................... 4988
Removal............................................................................................................................. 4988
Installation........................................................................................................................ 4988
Front Door Waist Seal................................................................................................................... 4989
Parts Location...................................................................................................................... 4989
Removal............................................................................................................................. 4989
Installation........................................................................................................................ 4989
Rear Door Waist Seal.................................................................................................................... 4990
Parts Location...................................................................................................................... 4990
Removal and Installation............................................................................................................ 4990
Front Door Weatherstrip................................................................................................................. 4991
Parts Location...................................................................................................................... 4991
Removal............................................................................................................................. 4991
Installation........................................................................................................................ 4992
Rear Door Weatherstrip.................................................................................................................. 4993
Parts Location...................................................................................................................... 4993
Removal and Installation............................................................................................................ 4993
Front Door Seal Finisher................................................................................................................ 4994
Parts Location...................................................................................................................... 4994
Removal............................................................................................................................. 4994
Installation........................................................................................................................ 4994
Rear Door Seal Finisher................................................................................................................. 4995
Parts Location...................................................................................................................... 4995
Removal............................................................................................................................. 4995
Installation........................................................................................................................ 4995
Tailgate Assembly (LH).................................................................................................................. 4996
Parts Location...................................................................................................................... 4996
Removal............................................................................................................................. 4996
Installation........................................................................................................................ 4997
Tailgate Assembly (RH).................................................................................................................. 4998
Parts Location...................................................................................................................... 4998
Removal............................................................................................................................. 4998
Installation........................................................................................................................ 4999
Tailgate Strikers....................................................................................................................... 5000
Adjustment.......................................................................................................................... 5000
Tailgate Stopper Assembly............................................................................................................... 5000
Parts Location...................................................................................................................... 5000
Removal............................................................................................................................. 5000
Installation........................................................................................................................ 5000
Tailgate Dove-Tail...................................................................................................................... 5001
Parts Location...................................................................................................................... 5001
Removal............................................................................................................................. 5001
Installation........................................................................................................................ 5001
Tailgate Dove-Tail Striker.............................................................................................................. 5002
Adjustment.......................................................................................................................... 5002
Tailgate Frame Cover (LH)............................................................................................................... 5003
Parts Location...................................................................................................................... 5003
Removal............................................................................................................................. 5003
Installation........................................................................................................................ 5003
Tailgate Frame Cover (RH)............................................................................................................... 5004
Removal............................................................................................................................. 5004
Installation........................................................................................................................ 5004
Tailgate Sash Trim Cover................................................................................................................ 5005
Parts Location...................................................................................................................... 5005
Removal............................................................................................................................. 5005
Installation........................................................................................................................ 5005
Tailgate Outer Weatherstrip............................................................................................................. 5006
Parts Location...................................................................................................................... 5006
Removal............................................................................................................................. 5006
Installation........................................................................................................................ 5006
Tailgate Center Weatherstrip............................................................................................................ 5007
Parts Location...................................................................................................................... 5007
Removal............................................................................................................................. 5007
Installation........................................................................................................................ 5007
Tailgate Main Weatherstrip.............................................................................................................. 5008
Parts Location...................................................................................................................... 5008
Removal............................................................................................................................. 5008
Installation........................................................................................................................ 5008
Spare Tire Carrier...................................................................................................................... 5009
Parts Location...................................................................................................................... 5009
Removal............................................................................................................................. 5009
Installation........................................................................................................................ 5009
Headlining.............................................................................................................................. 5010
Parts Location...................................................................................................................... 5010
Removal............................................................................................................................. 5010
Installation........................................................................................................................ 5011
Rear Air Deflector...................................................................................................................... 5012
Parts Location...................................................................................................................... 5012
Removal............................................................................................................................. 5012
Installation........................................................................................................................ 5012
Roof Moulding........................................................................................................................... 5014
Parts Location...................................................................................................................... 5014
Removal............................................................................................................................. 5014
Installation........................................................................................................................ 5014
Windshield.............................................................................................................................. 5016
Parts Location...................................................................................................................... 5016
Removal............................................................................................................................. 5016
Installation........................................................................................................................ 5017
Rear Quarter Side Glass................................................................................................................. 5021
Parts Location...................................................................................................................... 5021
Removal............................................................................................................................. 5021
Installation........................................................................................................................ 5021
Tailgate Glass.......................................................................................................................... 5023
Parts Location...................................................................................................................... 5023
Removal............................................................................................................................. 5023
Installation........................................................................................................................ 5024
Main Data and Specifications............................................................................................................ 5025
Special Tools........................................................................................................................... 5035
8G SEATS.................................................................................................................................. 5036
Service Precaution...................................................................................................................... 5036
Front Seat Assembly..................................................................................................................... 5037
Front Seat Assembly and Associated Parts............................................................................................ 5037
Removal............................................................................................................................. 5037
Installation........................................................................................................................ 5037
Disassembled View................................................................................................................... 5038
Disassembly......................................................................................................................... 5039
Reassembly.......................................................................................................................... 5040
Power Seat Assembly..................................................................................................................... 5041
General Description................................................................................................................. 5041
Disassembled View................................................................................................................... 5041
Disassembly......................................................................................................................... 5042
Reassembly.......................................................................................................................... 5044
Power Seat Switch....................................................................................................................... 5044
Removal............................................................................................................................. 5044
Installation........................................................................................................................ 5044
Front Tilt Motor / Rear Tilt Motor / Slide Motor / Recliner Motor....................................................................... 5045
Parts Location...................................................................................................................... 5045
Removal and Installation............................................................................................................ 5045
Seat Heater System...................................................................................................................... 5046
General Description................................................................................................................. 5046
Seat Heater Switch Removal and Installation......................................................................................... 5046
Heat Unit Parts Location............................................................................................................ 5046
Heat Unit Removal and Installation.................................................................................................. 5046
Rear Seat Assembly...................................................................................................................... 5047
Rear Seat Assembly and Associated Parts............................................................................................. 5047
Removal............................................................................................................................. 5047
Installation........................................................................................................................ 5047
Disassembled View (Split Type)...................................................................................................... 5048
Disassembly (Split Type)............................................................................................................ 5049
Reassembly (Split Type)............................................................................................................. 5050
Disassembled View (Bench Type)...................................................................................................... 5051
Disassembly (Bench Type)............................................................................................................ 5052
Reassembly (Bench Type)............................................................................................................. 5053
Rear Seat Foot Rest..................................................................................................................... 5053
Rear Seat Foot Rest and Associated Parts............................................................................................ 5053
Removal............................................................................................................................. 5054
Installation........................................................................................................................ 5054
Main Data and Specifications............................................................................................................ 5054
8H SECURITY AND LOCKS..................................................................................................................... 5056
Service Precaution...................................................................................................................... 5057
Front Door Lock Assembly................................................................................................................ 5057
Front Door Lock Assembly and Associated Parts....................................................................................... 5057
Removal............................................................................................................................. 5057
Installation........................................................................................................................ 5058
Front Outside Handle and Door Lock Cylinder............................................................................................. 5059
Front Outside Handle, Door Lock Cylinder and Associated Parts....................................................................... 5059
Removal............................................................................................................................. 5059
Installation........................................................................................................................ 5061
Rear Door Lock Assembly................................................................................................................. 5062
Rear Door Lock Assembly and Associated Parts........................................................................................ 5062
Removal............................................................................................................................. 5062
Installation........................................................................................................................ 5063
Rear Outside Handle..................................................................................................................... 5064
Rear Outside Handle and Associated Parts............................................................................................ 5064
Removal............................................................................................................................. 5064
Installation........................................................................................................................ 5065
Rear Door Inside Lock Knob Link......................................................................................................... 5065
Removal............................................................................................................................. 5065
Installation........................................................................................................................ 5065
Door Inside Lock Knob................................................................................................................... 5066
Removal............................................................................................................................. 5066
Installation........................................................................................................................ 5066
Door Inside Handle...................................................................................................................... 5066
Removal and Installation............................................................................................................ 5066
Tailgate Lock Assembly (LH)............................................................................................................. 5067
Tailgate Lock Assembly (LH) and Associated Parts.................................................................................... 5067
Removal............................................................................................................................. 5067
Installation........................................................................................................................ 5068
Tailgate Lock Assembly (RH)............................................................................................................. 5069
Tailgate Lock Assembly (RH) and Associated Parts.................................................................................... 5069
Removal............................................................................................................................. 5069
Installation........................................................................................................................ 5070
Tailgate Inside Lock Knob............................................................................................................... 5070
Removal............................................................................................................................. 5070
Installation........................................................................................................................ 5070
Tailgate Outside Handle and/or Tailgate Lock Cylinder................................................................................... 5071
Tailgate Outside Handle and/or Tailgate Lock Cylinder and Associated Parts.......................................................... 5071
Removal............................................................................................................................. 5071
Installation........................................................................................................................ 5072
Key..................................................................................................................................... 5073
Key Coding.......................................................................................................................... 5073
Key Styles.......................................................................................................................... 5073
Power Door Lock System.................................................................................................................. 5074
General Description................................................................................................................. 5074
Front Door Lock Actuator Removal.................................................................................................... 5074
Front Door Lock Actuator Installation............................................................................................... 5074
Rear Door Lock Actuator Removal..................................................................................................... 5074
Rear Door Lock Actuator Installation................................................................................................ 5075
Tailgate Lock Actuator Removal...................................................................................................... 5075
Tailgate Lock Actuator Installation................................................................................................. 5075
Anti-theft System....................................................................................................................... 5076
General Description................................................................................................................. 5076
Anti-theft & Keyless Entry Control Unit Removal..................................................................................... 5076
Anti-theft & Keyless Entry Control Unit Installation................................................................................ 5076
Anti-theft Indicator Removal........................................................................................................ 5076
Anti-theft Indicator Installation................................................................................................... 5077
Anti-theft Horn Removal............................................................................................................. 5077
Anti-Theft Horn Installation........................................................................................................ 5077
Engine Hood Switch Removal.......................................................................................................... 5077
Engine Hood Switch Installation..................................................................................................... 5077
Keyless Entry System.................................................................................................................... 5078
ID Code Registration................................................................................................................ 5078
Anti-theft & Keyless Entry Control Unit/Transmitter Replacement..................................................................... 5081
Main Data and Specifications............................................................................................................ 5082
8I SUN ROOF/CONVERTIBLE TOP.............................................................................................................. 5083
Service Precaution...................................................................................................................... 5083
Sun Roof Glass.......................................................................................................................... 5084
Sun Roof Glass and Associated Parts................................................................................................. 5084
Removal............................................................................................................................. 5084
Installation........................................................................................................................ 5085
Sun Roof Deflector...................................................................................................................... 5086
Removal............................................................................................................................. 5086
Installation........................................................................................................................ 5086
Sunshade................................................................................................................................ 5086
Disassembled View................................................................................................................... 5086
Removal............................................................................................................................. 5087
Installation........................................................................................................................ 5087
Sun Roof Frame Complete Assembly........................................................................................................ 5088
Sun Roof Frame Complete Assembly and Associated Parts............................................................................... 5088
Removal............................................................................................................................. 5088
Installation........................................................................................................................ 5089
Disassembled View................................................................................................................... 5089
Disassembly......................................................................................................................... 5089
Reassembly.......................................................................................................................... 5090
Sun Roof Drain Hose (Front Side)........................................................................................................ 5091
Sun Roof Drain Hose (Front Side) and Associated Parts............................................................................... 5091
Removal............................................................................................................................. 5091
Installation........................................................................................................................ 5091
Sun Roof Drain Hose (Rear Side)......................................................................................................... 5092
Sun Roof Drain Hose (Rear Side) and Associated Parts................................................................................ 5092
Removal............................................................................................................................. 5092
Installation........................................................................................................................ 5092
Sun Roof Switch......................................................................................................................... 5093
General Description................................................................................................................. 5093
Removal............................................................................................................................. 5093
Installation........................................................................................................................ 5093
Sun Roof Control Unit................................................................................................................... 5094
General Description................................................................................................................. 5094
Removal............................................................................................................................. 5094
Installation........................................................................................................................ 5094
Safety Stop Switch...................................................................................................................... 5094
General Description................................................................................................................. 5094
Removal............................................................................................................................. 5094
Installation........................................................................................................................ 5094
Limit Switch............................................................................................................................ 5095
General Description................................................................................................................. 5095
Removal............................................................................................................................. 5095
Installation........................................................................................................................ 5095
Sun Roof Motor.......................................................................................................................... 5095
Removal............................................................................................................................. 5095
Installation........................................................................................................................ 5095
Main Data and Specifications............................................................................................................ 5096
8J EXTERIOR / INTERIOR TRIM............................................................................................................... 5097
Service Precaution...................................................................................................................... 5098
Dash Side Trim Panel.................................................................................................................... 5099
Removal............................................................................................................................. 5099
Installation........................................................................................................................ 5099
Assist Grip............................................................................................................................. 5099
Parts Location...................................................................................................................... 5099
Removal and Installation............................................................................................................ 5099
Consoles................................................................................................................................ 5100
Consoles and Associated Parts....................................................................................................... 5100
Removal............................................................................................................................. 5100
Installation........................................................................................................................ 5101
Front Door Trim Panel................................................................................................................... 5102
Front Door Trim Panel and Associated Parts.......................................................................................... 5102
Removal............................................................................................................................. 5102
Installation........................................................................................................................ 5105
Rear Door Trim Panel.................................................................................................................... 5106
Rear Door Trim Panel and Associated Parts........................................................................................... 5106
Removal............................................................................................................................. 5106
Installation........................................................................................................................ 5107
Door Wood Panel Assembly................................................................................................................ 5109
Door Wood Panel Assembly and Associated Parts....................................................................................... 5109
Removal............................................................................................................................. 5109
Installation........................................................................................................................ 5109
Door Mirror............................................................................................................................. 5110
Door Mirror and Associated Parts.................................................................................................... 5110
Removal............................................................................................................................. 5110
Installation........................................................................................................................ 5110
Interior Trim Panels Luggage Side and Quarter Upper Trim Cover...................................................................... 5111
Interior Trim Panels Luggage Side, Quarter Upper Trim Cover and Associated Parts.................................................... 5111
Removal............................................................................................................................. 5111
Installation........................................................................................................................ 5113
Center Pillar and Roof Side Trim Cover.................................................................................................. 5113
Center Pillar, Roof Side Trim Cover and Associated Parts............................................................................ 5113
Removal............................................................................................................................. 5114
Installation........................................................................................................................ 5115
Front Pillar Trim Cover................................................................................................................. 5115
Front Pillar Trim Cover and Associated Parts........................................................................................ 5115
Removal............................................................................................................................. 5115
Installation........................................................................................................................ 5116
Center Pillar Assist Grip............................................................................................................... 5116
Parts Location...................................................................................................................... 5116
Removal and Installation............................................................................................................ 5116
Assist Grip............................................................................................................................. 5117
Parts Location...................................................................................................................... 5117
Removal and Installation............................................................................................................ 5117
Fuel Filler Lid Opener Cable............................................................................................................ 5118
Fuel Filler Lid Opener Cable and Associated Parts................................................................................... 5118
Removal............................................................................................................................. 5118
Installation........................................................................................................................ 5119
Fuel Filler Door........................................................................................................................ 5119
Parts Location...................................................................................................................... 5119
Removal............................................................................................................................. 5119
Installation........................................................................................................................ 5119
Rocker Protector (Without Wheel Opening Extension)...................................................................................... 5120
Rocker Protector (Without Wheel Opening Extension) and Associated Parts............................................................. 5120
Removal............................................................................................................................. 5120
Installation........................................................................................................................ 5120
Wheel Opening Extension and Rocker Protector Assembly................................................................................... 5121
Wheel Opening Extension, Rocker Protector Assembly and Associated Parts............................................................. 5121
Removal............................................................................................................................. 5121
Installation........................................................................................................................ 5122
Mud Flaps (With Wheel Opening Extension)................................................................................................ 5123
Mud Flaps (With Wheel Opening Extension) and Associated Parts....................................................................... 5123
Removal............................................................................................................................. 5123
Installation........................................................................................................................ 5123
Ventilation Assembly.................................................................................................................... 5124
Ventilation Assembly and Associated Parts........................................................................................... 5124
Removal............................................................................................................................. 5124
Installation........................................................................................................................ 5124
Tailgate Trim Panel (LH)................................................................................................................ 5125
Tailgate Trim Panel (LH) and Associated Parts....................................................................................... 5125
Removal............................................................................................................................. 5125
Installation........................................................................................................................ 5125
Tailgate Trim Panel (RH)................................................................................................................ 5126
Parts Location...................................................................................................................... 5126
Removal............................................................................................................................. 5126
Installation........................................................................................................................ 5126
Luggage Floor Box....................................................................................................................... 5127
Luggage Floor Box and Associated Parts.............................................................................................. 5127
Remove.............................................................................................................................. 5127
Installation........................................................................................................................ 5127
Rope Hook Set........................................................................................................................... 5127
Rope Hook Set and Associated Parts.................................................................................................. 5127
Removal............................................................................................................................. 5127
Installation........................................................................................................................ 5127
Power Door Mirror System................................................................................................................ 5128
General Description................................................................................................................. 5128
Door Mirror Switch Assembly (Control Switch, Folding Switch and Defogger Switch) Removal............................................ 5128
Installation........................................................................................................................ 5128
Power Door Mirror....................................................................................................................... 5128
General Description................................................................................................................. 5128
Removal and Installation............................................................................................................ 5128
Power Window System..................................................................................................................... 5129
General Description................................................................................................................. 5129
Power Window Switch Removal and Installation........................................................................................ 5129
Power Window Motor Removal and Installation......................................................................................... 5130
Main Data and Specifications............................................................................................................ 5131
Sec.9 RESTRAINTS.............................................................................................................................. 5132
9A SEAT BELT SYSTEM....................................................................................................................... 5132
Service Precaution...................................................................................................................... 5132
Seat Belt............................................................................................................................... 5133
Front Seat Belt and Associated Parts................................................................................................ 5133
Removal............................................................................................................................. 5133
Inspection.......................................................................................................................... 5133
Installation........................................................................................................................ 5134
Rear Seat Belt and Associated Parts................................................................................................. 5134
Removal............................................................................................................................. 5135
Inspection.......................................................................................................................... 5135
Installation........................................................................................................................ 5135
Front Seat Buckle Assembly.............................................................................................................. 5135
Removal............................................................................................................................. 5135
Installation........................................................................................................................ 5135
Rear Center Seat Belt / Buckle Assembly................................................................................................. 5136
Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................ 5136
Removal............................................................................................................................. 5136
Installation........................................................................................................................ 5136
Rear Seat Lock Assembly................................................................................................................. 5137
Removal............................................................................................................................. 5137
Installation........................................................................................................................ 5137
Rear Seat Lock Assembly (Bench Type).................................................................................................... 5137
Removal............................................................................................................................. 5137
Installation........................................................................................................................ 5137
Rear Seat Strikers...................................................................................................................... 5138
Removal............................................................................................................................. 5138
Installation........................................................................................................................ 5138
Child Seat Tether Anchor Bracket (Child Restraint)...................................................................................... 5138
General Description................................................................................................................. 5138
Child Seat Tether Anchor Bracket and Associated Parts............................................................................... 5138
Installation........................................................................................................................ 5138
Main Data and Specifications............................................................................................................ 5139
9J SUPPLEMENTAL RESTRAINT SYSTEM (SRS).................................................................................................... 5140
Service Precaution...................................................................................................................... 5140
General Description..................................................................................................................... 5141
SRS Component And Wiring Location View.................................................................................................. 5143
Component Description................................................................................................................... 5143
Definitions............................................................................................................................. 5146
Diagnosis............................................................................................................................... 5147
SRS Connector Body Face Views........................................................................................................... 5148
Repairs And Inspections Required After An Accident...................................................................................... 5148
On-Vehicle Service...................................................................................................................... 5149
Air Bag Assembly Handling / Shipping / Scrapping........................................................................................ 5150
Special Tools........................................................................................................................... 5159
Service Precautions for SRS Component Service........................................................................................... 5163
SRS Connectors.......................................................................................................................... 5164
Sensing And Diagnostic Module (SDM)..................................................................................................... 5166
Service Precautions................................................................................................................. 5166
Removal............................................................................................................................. 5166
Installation........................................................................................................................ 5166
Driver Air Bag Assembly................................................................................................................. 5168
Service Precautions................................................................................................................. 5168
Removal............................................................................................................................. 5168
Installation........................................................................................................................ 5169
Steering Wheel.......................................................................................................................... 5170
Service Precautions................................................................................................................. 5170
Removal............................................................................................................................. 5170
Installation........................................................................................................................ 5171
SRS Coil Assembly....................................................................................................................... 5173
Service Precautions................................................................................................................. 5173
Removal............................................................................................................................. 5173
Installation........................................................................................................................ 5174
Steering Column......................................................................................................................... 5176
Service Precautions................................................................................................................. 5176
Removal............................................................................................................................. 5176
Installation........................................................................................................................ 5178
Passenger Air Bag Assembly.............................................................................................................. 5180
Service Precautions................................................................................................................. 5180
Removal............................................................................................................................. 5180
Installation........................................................................................................................ 5181
Main Data and Specifications............................................................................................................ 5181
9J1 RESTRAINT CONTROL SYSTEM............................................................................................................... 5182
Service Precaution...................................................................................................................... 5182
Diagnostic Information.................................................................................................................. 5183
System Schematic........................................................................................................................ 5185
SRS Diagnostic System Check............................................................................................................. 5185
Chart A SDM Integrity Check............................................................................................................. 5187
Chart B "AIR BAG" Warning Lamp Comes "ON" Steady........................................................................................ 5189
Chart C "AIR BAG" Warning Lamp Does Not Come "ON" Steady (1/2).......................................................................... 5191
DTC 15 Passenger Deployment Loop Resistance High........................................................................................ 5194
DTC 16 Passenger Deployment loop Resistance Low......................................................................................... 5196
DTC 17 Passenger Deployment Loop Open................................................................................................... 5198
DTC 18 Passenger Deployment Loop Short To Ground........................................................................................ 5200
DTC 19 Passenger Deployment Loop Short To Voltage....................................................................................... 5202
DTC 21 Driver Deployment Loop Resistance High........................................................................................... 5204
DTC 22 Driver Deployment Loop Resistance Low............................................................................................ 5207
DTC 24 Driver Deployment Loop Short To Ground........................................................................................... 5209
DTC 25 Driver Deployment Loop Short To Voltage.......................................................................................... 5211
DTC 26 Driver Deployment Loop Open...................................................................................................... 5213
DTC 51 Deployment Event Commanded....................................................................................................... 5215
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range.................................................. 5217
DTC 61 Warning Lamp Circuit Failure..................................................................................................... 5219
DTC 71 Internal SDM Fault............................................................................................................... 5221
Sec.10 CONTROL SYSTEM.......................................................................................................................... 5223
10A CRUISE CONTROL SYSTEM.................................................................................................................. 5223
Service Precaution...................................................................................................................... 5223
General Description..................................................................................................................... 5223
Diagnosis............................................................................................................................... 5224
Brake Switch............................................................................................................................ 5224
Removal............................................................................................................................. 5224
Installation........................................................................................................................ 5224
Adjustment.......................................................................................................................... 5225
Clutch Switch........................................................................................................................... 5225
Removal and Installation............................................................................................................ 5225
Adjustment.......................................................................................................................... 5225
Starter Switch.......................................................................................................................... 5226
Removal............................................................................................................................. 5226
Installation........................................................................................................................ 5226
Cruise Control Main Switch.............................................................................................................. 5227
Removal............................................................................................................................. 5227
Installation........................................................................................................................ 5227
Cruise Control Switch (Combination Switch).............................................................................................. 5227
Removal and Installation............................................................................................................ 5227
Cruise Control Unit..................................................................................................................... 5228
Removal............................................................................................................................. 5228
Installation........................................................................................................................ 5228
Cruise Actuator......................................................................................................................... 5228
Actuator Cable Diagram.............................................................................................................. 5228
Removal............................................................................................................................. 5229
Installation........................................................................................................................ 5229
Adjustment.......................................................................................................................... 5229
Mode Switch............................................................................................................................. 5230
Removal and Installation............................................................................................................ 5230
(UE) RODEO.......................................................................................................................................... 3
Sec.0 GENERAL INFORMATION..................................................................................................................... 4
0A GENERAL INFORMATION.................................................................................................................... 4
General Repair Instruction.............................................................................................................. 4
Illustration Arrows..................................................................................................................... 5
Identification.......................................................................................................................... 6
Theft Prevention Standard............................................................................................................... 8
Lifting Instructions.................................................................................................................... 13
Standard Bolts Torque Specifications.................................................................................................... 15
Abbreviations Charts.................................................................................................................... 16
Service Parts Identification Plate...................................................................................................... 17
0B MAINTENANCE AND LUBRICATION............................................................................................................ 18
Maintenance Schedule List............................................................................................................... 18
Explanation of Complete Vehicle Maintenance Schedule.................................................................................... 22
Recommended Fluids and Lubricants................................................................................................... 25
Lubricant Viscosity Chart............................................................................................................... 26
Recommended Liquid Gasket........................................................................................................... 28
Recommended Thread Locking Agents................................................................................................... 29
Maintenance Service Data................................................................................................................ 30
Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................................................ 31
1A HVAC SYSTEMS........................................................................................................................... 31
Service Precaution...................................................................................................................... 32
Heating and Ventilation System.......................................................................................................... 32
General Description................................................................................................................. 32
Wiring Diagram...................................................................................................................... 36
Diagnosis........................................................................................................................... 37
Individual Inspection............................................................................................................... 41
Heater Unit............................................................................................................................. 43
Heater Unit and Associated Parts.................................................................................................... 43
Removal............................................................................................................................. 43
Installation........................................................................................................................ 44
Heater Core and / or Mode Door.......................................................................................................... 44
Disassembled View................................................................................................................... 44
Removal............................................................................................................................. 44
Inspection.......................................................................................................................... 45
Installation........................................................................................................................ 45
Heater Mode Control Link Unit........................................................................................................... 46
Disassembled View................................................................................................................... 46
Removal............................................................................................................................. 46
Installation........................................................................................................................ 47
Heater Temperature Control Link Unit.................................................................................................... 47
Disassembled View................................................................................................................... 47
Removal............................................................................................................................. 47
Installation........................................................................................................................ 48
Blower Assembly......................................................................................................................... 48
Blower Assembly and Associated Parts................................................................................................ 48
Removal............................................................................................................................. 48
Installation........................................................................................................................ 49
Blower Link Unit and / or Mode door..................................................................................................... 49
Disassembled View................................................................................................................... 49
Removal............................................................................................................................. 49
Installation........................................................................................................................ 50
Blower Motor............................................................................................................................ 51
Blower Motor and Associated Parts................................................................................................... 51
Removal............................................................................................................................. 51
Installation........................................................................................................................ 51
Rear Heater Duct, Defroster Nozzle and Ventilation Duct................................................................................. 52
Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts........................................................... 52
Removal............................................................................................................................. 52
Installation........................................................................................................................ 53
Control Lever Assembly and / or Control Cable........................................................................................... 53
Control Lever Assembly, Control Cable and Associated Parts.......................................................................... 53
Removal............................................................................................................................. 54
Installation........................................................................................................................ 55
Control Panel Illumination Bulb......................................................................................................... 56
Control Panel Illumination Bulb and Associated Parts................................................................................ 56
Removal............................................................................................................................. 56
Installation........................................................................................................................ 56
Resistor................................................................................................................................ 56
Resistor and Associated Parts....................................................................................................... 56
Removal............................................................................................................................. 56
Installation........................................................................................................................ 56
Air Conditioning System................................................................................................................. 57
General Description..................................................................................................................... 57
Diagnosis............................................................................................................................... 65
Individual Inspection................................................................................................................... 74
General Repair Procedure............................................................................................................ 75
Leak Check.......................................................................................................................... 77
Compressor Assembly..................................................................................................................... 82
Compressor Assembly and Associated Parts............................................................................................ 82
Removal............................................................................................................................. 82
Installation........................................................................................................................ 83
New Compressor Installation......................................................................................................... 83
Condenser Assembly...................................................................................................................... 84
Condenser Assembly and Associated Parts............................................................................................. 84
Removal............................................................................................................................. 84
Installation........................................................................................................................ 84
Condenser Fan Motor..................................................................................................................... 85
Condenser Fan Motor and Associated Parts............................................................................................ 85
Removal............................................................................................................................. 85
Installation........................................................................................................................ 85
Receiver / Drier........................................................................................................................ 86
Receiver / Drier and Associated Parts............................................................................................... 86
Removal............................................................................................................................. 86
Installation........................................................................................................................ 86
Pressure Switch......................................................................................................................... 87
Pressure Switch and Associated Parts................................................................................................ 87
Removal............................................................................................................................. 87
Installation........................................................................................................................ 87
Evaporator Assembly..................................................................................................................... 88
Evaporator Assembly and Associated Parts............................................................................................ 88
Removal............................................................................................................................. 88
Installation........................................................................................................................ 89
Electronic Thermostat, Evaporator Core and/or Expansion Valve........................................................................... 89
Disassembled View................................................................................................................... 89
Removal............................................................................................................................. 90
Installation........................................................................................................................ 90
Refrigerant Line........................................................................................................................ 91
Refrigerant Line and Associated Parts............................................................................................... 91
Removal............................................................................................................................. 92
Installation........................................................................................................................ 92
Main Data And Specifications............................................................................................................ 92
Compressor.............................................................................................................................. 95
Service Precaution.................................................................................................................. 95
General Description..................................................................................................................... 95
Diagnosis............................................................................................................................... 96
Magnetic Clutch Assembly (DKV-14D Type)................................................................................................. 97
Parts Location View................................................................................................................. 97
Removal............................................................................................................................. 97
Inspection and Repair............................................................................................................... 98
Installation........................................................................................................................ 99
Compressor Oil.......................................................................................................................... 100
Oil Specification................................................................................................................... 100
Handling of Oil..................................................................................................................... 100
Compressor Oil Check................................................................................................................ 100
Checking and Adjusting Oil Quantity for Used Compressor............................................................................. 100
Checking and Adjusting for Compressor Replacement................................................................................... 101
Contamination of Compressor Oil..................................................................................................... 101
Oil Return Operation................................................................................................................ 101
Replacement of Component Parts...................................................................................................... 101
Main Data and Specifications............................................................................................................ 102
Special Tools........................................................................................................................... 104
Sec.2 STEERING................................................................................................................................ 105
2A POWER-ASSISTED STEERING SYSTEM......................................................................................................... 105
Service Precaution...................................................................................................................... 106
Diagnosis............................................................................................................................... 106
General Description..................................................................................................................... 112
Power Steering System Test.............................................................................................................. 114
Maintenance............................................................................................................................. 115
Fluid Level............................................................................................................................. 115
Bleeding The Power Steering System...................................................................................................... 115
Bleeding Procedure...................................................................................................................... 115
Flushing The Power Steering System...................................................................................................... 115
Steering Wheel Free Play Inspection..................................................................................................... 116
Front End Alignment Inspection and Adjustment........................................................................................... 116
Main Data and Specifications............................................................................................................ 120
Special Tools........................................................................................................................... 121
Power Steering Unit..................................................................................................................... 122
Power Steering Unit and Associated Parts............................................................................................ 122
Removal............................................................................................................................. 122
Installation (4ﾗ2 Model)............................................................................................................ 123
Installation (4ﾗ4 Model)............................................................................................................ 123
Power Steering Unit Disassembled View............................................................................................... 124
Disassembly......................................................................................................................... 124
Inspection and Repair............................................................................................................... 124
Reassembly.......................................................................................................................... 124
Main Data and Specifications........................................................................................................ 125
Special Tools....................................................................................................................... 125
Power Steering Pump..................................................................................................................... 126
Power Steering Pump and Associated Parts............................................................................................ 126
Removal............................................................................................................................. 126
Installation........................................................................................................................ 126
Power Steering Pump Disassembled View............................................................................................... 127
Disassembly......................................................................................................................... 127
Inspection and Repair............................................................................................................... 128
Reassembly.......................................................................................................................... 128
Main Data and Specifications........................................................................................................ 130
Transfer Gear Assembly.................................................................................................................. 131
Transfer Gear Assembly and Associated Parts......................................................................................... 131
Removal............................................................................................................................. 131
Inspection and Repair............................................................................................................... 131
Installation........................................................................................................................ 131
Supplemental Restraint System Steering Wheel & Column................................................................................... 132
Service Precaution.................................................................................................................. 132
SRS Connectors...................................................................................................................... 132
Inflator Module......................................................................................................................... 134
Inflator Module and Associated Parts................................................................................................ 134
Removal............................................................................................................................. 134
Inspection and Repair............................................................................................................... 135
Installation........................................................................................................................ 135
Steering Wheel.......................................................................................................................... 136
Steering Wheel and Associated Parts................................................................................................. 136
Removal............................................................................................................................. 136
Installation........................................................................................................................ 138
Combination Switch...................................................................................................................... 139
Combination Switch and Associated Parts............................................................................................. 139
Removal............................................................................................................................. 139
Installation........................................................................................................................ 141
Lock Cylinder........................................................................................................................... 143
Lock Cylinder and Associated Parts.................................................................................................. 143
Removal............................................................................................................................. 143
Installation........................................................................................................................ 145
System Inspection................................................................................................................... 146
Steering Column......................................................................................................................... 147
Steering Column and Associated Parts................................................................................................ 147
Removal............................................................................................................................. 147
Insepction.......................................................................................................................... 150
Installation........................................................................................................................ 151
System Inspection................................................................................................................... 152
Supplemental Restraint System Steering Wheel & Column and Associated Parts.............................................................. 153
Main Data and Specifications........................................................................................................ 153
Special Tools....................................................................................................................... 153
Sec.3 SUSPENSION.............................................................................................................................. 154
3C FRONT SUSPENSION....................................................................................................................... 154
Service Precaution...................................................................................................................... 154
General Description..................................................................................................................... 155
Diagnosis............................................................................................................................... 155
Shock Absorber.......................................................................................................................... 158
Shock Absorber and Associated Parts..................................................................................................... 158
Removal............................................................................................................................. 158
Inspection and Repair............................................................................................................... 158
Installation........................................................................................................................ 158
Stabilizer Bar.......................................................................................................................... 159
Stabilizer Bar and Associated Parts................................................................................................. 159
Removal............................................................................................................................. 159
Inspection and Repair............................................................................................................... 159
Installation........................................................................................................................ 159
Torsion Bar............................................................................................................................. 160
Torsion Bar and Associated Parts.................................................................................................... 160
Removal............................................................................................................................. 160
Inspection and Repair............................................................................................................... 161
Installation........................................................................................................................ 161
Knuckle................................................................................................................................. 163
Knuckle and Associated Parts........................................................................................................ 163
Removal............................................................................................................................. 163
Inspection and Repair............................................................................................................... 164
Installation........................................................................................................................ 164
Upper Control Arm....................................................................................................................... 166
Upper Control Arm and Associated Parts.............................................................................................. 166
Removal............................................................................................................................. 166
Inspection and Repair............................................................................................................... 167
Installation........................................................................................................................ 167
Lower Control Arm....................................................................................................................... 169
Lower Control Arm and Associated Parts.............................................................................................. 169
Removal............................................................................................................................. 169
Inspection and Repair............................................................................................................... 170
Installation........................................................................................................................ 171
Upper Ball Joint........................................................................................................................ 172
Upper Ball Joint and Associated Parts............................................................................................... 172
Removal............................................................................................................................. 172
Inspection and Repair............................................................................................................... 173
Installation........................................................................................................................ 173
Lower Ball Joint........................................................................................................................ 174
Lower Ball Joint and Associated Parts............................................................................................... 174
Removal............................................................................................................................. 174
Inspection and Repair............................................................................................................... 175
Installation........................................................................................................................ 175
Main Data and Specifications............................................................................................................ 176
Special Tools........................................................................................................................... 177
3D REAR SUSPENSION........................................................................................................................ 178
Service Precaution...................................................................................................................... 178
General Description..................................................................................................................... 178
Diagnosis............................................................................................................................... 179
Coil Spring............................................................................................................................. 182
Coil Spring and Associated Parts.................................................................................................... 182
Removal............................................................................................................................. 182
Inspection and Repair............................................................................................................... 183
Installation........................................................................................................................ 183
Shock Absorber.......................................................................................................................... 184
Shock Absorber and Associated Parts................................................................................................. 184
Removal............................................................................................................................. 184
Inspection and Repair............................................................................................................... 184
Installation........................................................................................................................ 184
Trailing Link........................................................................................................................... 185
Trailing Link and Associated Parts.................................................................................................. 185
Removal............................................................................................................................. 185
Inspection and Repair............................................................................................................... 185
Installation........................................................................................................................ 186
Upper Link.............................................................................................................................. 187
Upper Link and Associated Parts..................................................................................................... 187
Removal............................................................................................................................. 187
Inspection and Repair............................................................................................................... 187
Installation........................................................................................................................ 188
Lateral Rod............................................................................................................................. 189
Lateral Rod and Associated Parts.................................................................................................... 189
Removal............................................................................................................................. 189
Inspection and Repair............................................................................................................... 189
Installation........................................................................................................................ 190
Stabilizer Bar.......................................................................................................................... 191
Stabilizer Bar and Associated Parts................................................................................................. 191
Removal............................................................................................................................. 191
Inspection and Repair............................................................................................................... 191
Installation........................................................................................................................ 192
Main Data and Specifications............................................................................................................ 193
Special Tools........................................................................................................................... 195
3E WHEEL AND TIRE SYSTEM.................................................................................................................. 196
Service Precaution...................................................................................................................... 196
General Description..................................................................................................................... 197
Diagnosis............................................................................................................................... 198
Wheel................................................................................................................................... 206
Wheel and Associated Parts.......................................................................................................... 206
Removal............................................................................................................................. 206
Installation........................................................................................................................ 206
Tire.................................................................................................................................... 207
Tire Replacement.................................................................................................................... 207
General Balance Procedure............................................................................................................... 207
Balancing Wheel and Tire................................................................................................................ 208
Main Data and Specifications............................................................................................................ 209
Sec.4 DRIVELINE/AXLE.......................................................................................................................... 210
4A1 DIFFERENTIAL (FRONT)................................................................................................................... 210
Service Precaution...................................................................................................................... 210
Front Drive Axle........................................................................................................................ 211
Diagnosis............................................................................................................................... 211
Pinion Shaft Oil Seal................................................................................................................... 212
Pinion Shaft Oil Seal and Associated Parts.......................................................................................... 212
Removal............................................................................................................................. 212
Inspection and Repair............................................................................................................... 213
Installation........................................................................................................................ 213
Front Drive Axle Assembly............................................................................................................... 214
Front Drive Axle Assembly and Associated Parts...................................................................................... 214
Removal............................................................................................................................. 215
Installation........................................................................................................................ 216
Differential Assembly................................................................................................................... 217
Disassembled View................................................................................................................... 217
Disassembly......................................................................................................................... 218
Reassembly.......................................................................................................................... 220
Differential Cage Assembly.............................................................................................................. 228
Disassembled View................................................................................................................... 228
Disassembly......................................................................................................................... 228
Inspection and Repair............................................................................................................... 229
Reassembly.......................................................................................................................... 229
Main Data and Specifications............................................................................................................ 231
Special Tools........................................................................................................................... 234
4A2 DIFFERENTIAL (REAR).................................................................................................................... 236
Service Precaution...................................................................................................................... 236
General Description..................................................................................................................... 237
Diagnosis............................................................................................................................... 238
Axle Housing............................................................................................................................ 240
Axle Housing and Associated Parts................................................................................................... 240
Removal............................................................................................................................. 240
Installation........................................................................................................................ 242
Axle Shaft, Oil Seal and Bearing........................................................................................................ 242
Axle Shaft and Associated Parts..................................................................................................... 242
Removal............................................................................................................................. 243
Inspection.......................................................................................................................... 243
Installation........................................................................................................................ 243
Pinion Oil Seal......................................................................................................................... 245
Pinion Oil Seal and Associated Parts................................................................................................ 245
Removal............................................................................................................................. 245
Inspection and Repair............................................................................................................... 246
Installation........................................................................................................................ 246
Differential Assembly................................................................................................................... 248
Disassembled View................................................................................................................... 248
Inspecting the Axle Before Disassembly.............................................................................................. 249
Disassembly......................................................................................................................... 249
Inspection and Repair............................................................................................................... 251
Reassembly.......................................................................................................................... 251
Side Bearing Preload Adjustment..................................................................................................... 255
Pinion Installation................................................................................................................. 256
Determination of Backlash & Preload Shims........................................................................................... 257
Backlash Adjustment................................................................................................................. 258
Gear Tooth Pattern Check............................................................................................................ 258
Adjustments Affecting Tooth Contact................................................................................................. 259
Differential Case Assembly.............................................................................................................. 260
Disassembled View................................................................................................................... 260
Disassembly......................................................................................................................... 261
Inspection and Repair............................................................................................................... 261
Reassembly.......................................................................................................................... 261
Limited Slip Differential Assembly...................................................................................................... 262
Disassembled View................................................................................................................... 262
Disassembly......................................................................................................................... 262
Inspection and Repair............................................................................................................... 264
Reassembly.......................................................................................................................... 264
Main Data And Specifications............................................................................................................ 266
Special Tools........................................................................................................................... 268
4B DRIVELINE CONTROL SYSTEM............................................................................................................... 270
Service Precaution...................................................................................................................... 270
Shift On The Fly System................................................................................................................. 271
Outline of Shift on The Fly System...................................................................................................... 271
System Diagrams..................................................................................................................... 271
Normal Operation.................................................................................................................... 272
Retrial............................................................................................................................. 273
Functions of Indicator Lamp............................................................................................................. 275
Diagnosis............................................................................................................................... 276
Before Judging That Troubles Occur (Unfaulty mode).................................................................................. 276
Parts Location...................................................................................................................... 277
Wiring Diagram...................................................................................................................... 278
Connector List...................................................................................................................... 280
Diagnosis of The Faults Based on the Status of 4WD Indicator Lamp, 4WD Switch and T/F Change Lever.................................. 281
Shift On The Fly Vacuum Piping and Electrical Equipment................................................................................. 286
Vacuum Piping Diagram............................................................................................................... 286
Actuator Assembly................................................................................................................... 286
Vacuum Tank......................................................................................................................... 286
Inspection and Repair................................................................................................................... 287
Vacuum Piping....................................................................................................................... 287
Check Valve......................................................................................................................... 287
VSV Assembly........................................................................................................................ 288
Functional Detective Switch......................................................................................................... 288
Motor Actuator Assembly............................................................................................................. 288
Transfer Position Switch............................................................................................................ 289
4WD Control Unit........................................................................................................................ 290
4WD Control Unit Associated Parts................................................................................................... 290
Removal............................................................................................................................. 291
Installation........................................................................................................................ 291
4C DRIVE SHAFT SYSTEM..................................................................................................................... 292
Service Precaution...................................................................................................................... 292
General Description..................................................................................................................... 293
Diagnosis............................................................................................................................... 293
Front Hub and Disc (2WD Model).......................................................................................................... 294
Disassembled View................................................................................................................... 294
Disassembly......................................................................................................................... 294
Inspection and Repair............................................................................................................... 295
Reassembly.......................................................................................................................... 296
Front Hub and Disc (4WD Model).......................................................................................................... 299
Disassembled View................................................................................................................... 299
Disassembly......................................................................................................................... 299
Inspection and Repair............................................................................................................... 300
Reassembly.......................................................................................................................... 301
Front Drive Shaft Joint................................................................................................................. 304
Front Drive Shaft Joints Replacement................................................................................................ 304
Front Axle Drive Shaft.................................................................................................................. 305
Front Axle Drive Shaft and Associated Parts......................................................................................... 305
Disassembly......................................................................................................................... 306
Inspection And Repair............................................................................................................... 307
Bushing Replacement................................................................................................................. 307
Reassembly.......................................................................................................................... 307
Shift On The Fly System................................................................................................................. 310
Shift On The Fly System and Associated Parts........................................................................................ 310
Disassembly......................................................................................................................... 310
Inspection And Repair............................................................................................................... 312
Reassembly.......................................................................................................................... 315
Main Data and Specifications........................................................................................................ 317
Special Tools....................................................................................................................... 319
Propeller Shaft......................................................................................................................... 320
General Description..................................................................................................................... 320
Universal Joint......................................................................................................................... 321
Diagnosis of Propeller Shaft and Universal Joint........................................................................................ 322
Front Propeller Shaft................................................................................................................... 323
Front Propeller Shaft and Associated Parts.......................................................................................... 323
Removal............................................................................................................................. 323
Installation........................................................................................................................ 323
Disassembly......................................................................................................................... 324
Universal Joint Disassembly......................................................................................................... 325
Inspection and Repair............................................................................................................... 326
Universal Joint Reassembly.......................................................................................................... 327
Reassembly.......................................................................................................................... 328
Main Data and Specifications........................................................................................................ 329
Rear Propeller Shaft.................................................................................................................... 330
Inspection.............................................................................................................................. 334
Rear Propeller Shaft and Associated Parts........................................................................................... 330
Removal............................................................................................................................. 330
Installation........................................................................................................................ 330
Slip Joint Disassembly.............................................................................................................. 331
Universal Joint Disassembly......................................................................................................... 332
Universal Joint Reassembly.......................................................................................................... 335
Slip Joint Reassembly............................................................................................................... 336
Main Data and Specifications........................................................................................................ 337
4D TRANSFER CASE.......................................................................................................................... 338
Service Precaution...................................................................................................................... 338
General Description..................................................................................................................... 339
Transfer Rear Oil Seal.................................................................................................................. 341
Transfer Rear Oil Seal and Associated Parts......................................................................................... 341
Removal............................................................................................................................. 341
Installation........................................................................................................................ 341
Transfer Case Assembly (A/T)............................................................................................................ 343
Transfer Case Assembly (A/T) and Associated Parts................................................................................... 343
Removal............................................................................................................................. 344
Installation........................................................................................................................ 345
Transfer Rear Case Assembly (A/T)....................................................................................................... 348
Transfer Rear Case Assembly (A/T) and Associated Parts.............................................................................. 348
Removal............................................................................................................................. 348
Installation........................................................................................................................ 350
Transfer Rear Cover Assembly........................................................................................................ 353
Disassembly......................................................................................................................... 353
Inspection and Repair............................................................................................................... 354
Reassembly.......................................................................................................................... 354
Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)........................................................................... 356
Disassembled View................................................................................................................... 356
Disassembly......................................................................................................................... 357
Inspection and Repair............................................................................................................... 358
Reassembly.......................................................................................................................... 358
Transfer Case Assembly.................................................................................................................. 360
Disassembled View................................................................................................................... 360
Disassembly......................................................................................................................... 361
Inspection and Repair............................................................................................................... 364
Reassembly.......................................................................................................................... 367
Main Data and Specifications............................................................................................................ 374
Special Tools........................................................................................................................... 377
Sec.5 BRAKES.................................................................................................................................. 378
5A BRAKE CONTROL SYSTEM................................................................................................................... 378
Service Precaution...................................................................................................................... 379
General Description..................................................................................................................... 380
Functional Description.............................................................................................................. 381
System Components................................................................................................................... 387
Electronic Hydraulic Control Unit (EHCU)............................................................................................ 387
ABS Warning Light................................................................................................................... 387
Wheel Speed Sensor.................................................................................................................. 387
G-Sensor............................................................................................................................ 387
Normal and Anti-lock Braking........................................................................................................ 387
Brake Pedal Travel.................................................................................................................. 387
Acronyms and Abbreviations.......................................................................................................... 387
General Diagnosis....................................................................................................................... 388
General Information................................................................................................................. 388
ABS Service Precautions............................................................................................................. 388
Computer System Service Precautions................................................................................................. 388
General Service Precautions......................................................................................................... 388
Note on Intermittents............................................................................................................... 388
Test Driving ABS Complaint Vehicles................................................................................................. 389
"ABS" Warning Light................................................................................................................. 389
Normal Operation.................................................................................................................... 389
Tech 2 Scan Tool.................................................................................................................... 390
DATA LIST........................................................................................................................... 393
ACTUATOR TEST....................................................................................................................... 394
Tech 2 Service Bleed................................................................................................................ 398
Basic Diagnostic Flow Chart......................................................................................................... 399
Basic Inspection Procedure.......................................................................................................... 400
EHCU Connector Pin-out Checks........................................................................................................... 401
Circuit Diagram..................................................................................................................... 402
Connector List...................................................................................................................... 405
Part Location....................................................................................................................... 406
Symptom Diagnosis....................................................................................................................... 407
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate...................................................................... 407
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................ 408
Chart A-2 Uneven Braking Occurs While ABS Works..................................................................................... 408
Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2)....................................................................... 408
Chart A-3, TA-3 The Wheels Are Locked............................................................................................... 409
Chart A-4 Brake Pedal Feed Is Abnormal.............................................................................................. 410
Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................ 411
Diagnostic Trouble Codes................................................................................................................ 412
Diagnosis By "ABS" Warning Light Illumination Pattern................................................................................... 414
Diagnostic Trouble Codes (DTCs)..................................................................................................... 415
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................ 417
Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial communications))....................................... 418
Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial communications))................................... 418
Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications)).................................................. 418
Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications))............................................. 419
Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications)).............................................. 419
Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications))................................................. 419
Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial communications)), 4WD State Input Signal .... 420
Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial communications))............................................ 420
Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash out) / C0265, C0266 (Serial communications))..................................... 421
Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial communications))........................... 421
Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial communications))................................ 421
Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash out) / C0241, C0243 (Serial communications))........................... 422
Chart B-14 FR Dump Solenoid Coil Failure (DTC 44(Flash out) / C0242, C0244 (Serial communications))................................. 422
Chart B-15 Rear Isolation Solenoid Coil Failure (DTC 45 (Flash out) / C0251, C0253 (Serial communications))......................... 422
Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash out) / C0252, C0254 (Serial communications)).............................. 423
Chart B-17 FL Speed Sensor Open or Shorted (DTC 51 (Flash out) / C0225 (Serial communications))..................................... 423
Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash out) / C0221 (Serial communications))..................................... 424
Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash out) / C0235 (Serial communications))................................... 425
Chart B-20 FL Speed Sensor Missing (DTC 61 (Flash out) / C0226, C0227 (Serial communications))...................................... 426
Chart B-21 FR Speed Sensor Missing (DTC 62 (Flash out) / C0222, C0223 (Serial communications))...................................... 427
Chart B-22 Rear Speed Sensor Missing (DTC 63 (Flash out) / C0236, C0237 (Serial communications)).................................... 428
Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal (DTC 64 (Flash out) / C0229 (Serial communications)).................. 429
Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash out) / C0238 (Serial communications))....................................... 430
Unit Inspection Procedure............................................................................................................... 431
Chart C-1-1 FL Sensor Output Inspection Procedure................................................................................... 431
Chart C-1-2 FR Sensor Output Inspection Procedure................................................................................... 432
Chart C-1-3 Rear Sensor Output Inspection Procedure................................................................................. 432
Chart TC-1 Sensor Output Inspection Procedure....................................................................................... 433
Special Tools........................................................................................................................... 434
5B ANTI-LOCK BRAKE SYSTEM................................................................................................................. 435
Service Precaution...................................................................................................................... 435
Electronic Hydraulic Control Unit....................................................................................................... 436
Electronic Hydraulic Control Unit and Associated Parts.............................................................................. 436
Removal............................................................................................................................. 436
Disassembled View................................................................................................................... 437
Disassembly......................................................................................................................... 437
Reassembly.......................................................................................................................... 437
Installation........................................................................................................................ 437
Front Wheel Speed Sensor................................................................................................................ 438
Front Wheel Speed Sensor and Associated Parts....................................................................................... 438
Removal............................................................................................................................. 438
Inspection and Repair............................................................................................................... 438
Installation........................................................................................................................ 438
Rear Wheel Speed Sensor................................................................................................................. 439
Removal............................................................................................................................. 439
Inspection and Repair............................................................................................................... 439
Installation........................................................................................................................ 439
5C POWER-ASSISTED BRAKE SYSTEM............................................................................................................ 440
Service Precaution...................................................................................................................... 441
General Description..................................................................................................................... 441
Diagnosis............................................................................................................................... 445
General Diagnosis....................................................................................................................... 446
Hydraulic Brakes........................................................................................................................ 449
Filling Master Cylinder Reservoir................................................................................................... 449
Deterioration of Brake Fluid........................................................................................................ 449
Leakage of Brake Fluid.............................................................................................................. 449
Bleeding Brake Hydraulic System..................................................................................................... 449
Flushing Brake Hydraulic System..................................................................................................... 450
Brake Pipes and Hoses............................................................................................................... 450
Brake Hose Inspection............................................................................................................... 450
Front Caliper Brake Hose................................................................................................................ 451
Front Caliper Brake Hose and Associated Parts....................................................................................... 451
Removal............................................................................................................................. 451
Installation........................................................................................................................ 451
Rear Axle Brake Hose.................................................................................................................... 452
Rear Axle Brake Hose and Associated Parts........................................................................................... 452
Removal............................................................................................................................. 452
Installation........................................................................................................................ 452
Brake Pipe.............................................................................................................................. 453
Removal............................................................................................................................. 453
Installation........................................................................................................................ 453
P & B (Proportioning and Bypass) Valve.................................................................................................. 454
P & B (Proportioning and Bypass) Valve Sectional View............................................................................... 454
Removal............................................................................................................................. 454
Installation........................................................................................................................ 454
Main Data and Specifications........................................................................................................ 455
Brake Pedal............................................................................................................................. 456
Checking Pedal Height............................................................................................................... 456
Checking Pedal Travel............................................................................................................... 456
Brake Pedal and Associated Parts.................................................................................................... 457
Removal............................................................................................................................. 457
Installation........................................................................................................................ 457
Stoplight Switch........................................................................................................................ 458
Parts Location...................................................................................................................... 458
Removal............................................................................................................................. 458
Installation........................................................................................................................ 458
Main Data and Specifications........................................................................................................ 459
Fluid Reservoir Tank.................................................................................................................... 460
Fluid Reservoir Tank and Associated Parts........................................................................................... 460
Removal............................................................................................................................. 460
Installation........................................................................................................................ 460
Master Cylinder Assembly................................................................................................................ 461
Master Cylinder Assembly and Associated Parts....................................................................................... 461
Removal............................................................................................................................. 461
Inspection and Repair............................................................................................................... 461
Installation........................................................................................................................ 462
Main Data and Specifications........................................................................................................ 463
Special Tools....................................................................................................................... 463
Vacuum Booster Assembly................................................................................................................. 464
Vacuum Booster Assembly and Associated Parts........................................................................................ 464
Removal............................................................................................................................. 464
Inspection and Repair............................................................................................................... 464
Installation........................................................................................................................ 465
Exterior Components..................................................................................................................... 467
Exterior Components and Associated Parts............................................................................................ 467
Removal............................................................................................................................. 467
Inspection and Repair............................................................................................................... 468
Installation........................................................................................................................ 468
Vacuum Booster Overhaul................................................................................................................. 468
Vacuum Booster...................................................................................................................... 468
Main Data and Specifications........................................................................................................ 469
Special Tools....................................................................................................................... 470
Front Disc Brake Pads................................................................................................................... 471
Front Disc Brake Pads Inspection.................................................................................................... 471
Front Disc Brake Pads and Associated Parts.......................................................................................... 471
Removal............................................................................................................................. 472
Installation........................................................................................................................ 472
Front Disc Brake Rotor.................................................................................................................. 474
Inspection.......................................................................................................................... 474
Replacing Brake Rotors.............................................................................................................. 474
Refinishing Brake Rotors............................................................................................................ 474
Front Disc Brake Caliper Assembly....................................................................................................... 475
Front Disc Brake Caliper Assembly and Associated Parts.............................................................................. 475
Removal............................................................................................................................. 476
Installation........................................................................................................................ 476
Front Disc Brake Caliper................................................................................................................ 478
Front Disc Brake Caliper Disassembled View.......................................................................................... 478
Disassembly......................................................................................................................... 478
Inspection and Repair............................................................................................................... 479
Reassembly.......................................................................................................................... 479
Main Data and Specifications........................................................................................................ 481
Rear Disc Brake Pads (4ﾗ4 Model)........................................................................................................ 482
Brake Pads Inspection............................................................................................................... 482
Brake Pads and Associated Parts..................................................................................................... 482
Removal............................................................................................................................. 483
Installation........................................................................................................................ 483
Rear Disc Brake Rotor (4ﾗ4 Model)....................................................................................................... 485
Inspection.......................................................................................................................... 485
Replacing Brake Rotors.............................................................................................................. 485
Refinishing Brake Rotors............................................................................................................ 485
Rear Drum (In Disc) Inside Diameter Check........................................................................................... 486
Rear Disc Brake Caliper Assembly (4ﾗ4 Model)............................................................................................ 487
Rear Disc Brake Caliper Assembly and Associated Parts............................................................................... 487
Removal............................................................................................................................. 487
Installation........................................................................................................................ 488
Rear Disc Brake Caliper (4ﾗ4 Model)..................................................................................................... 489
Rear Disc Brake Caliper Disassembled View........................................................................................... 489
Disassembly......................................................................................................................... 490
Inspection and Repair............................................................................................................... 490
Reassembly.......................................................................................................................... 490
Main Data and Specifications (4ﾗ4 Model)............................................................................................ 492
Brake Lining............................................................................................................................ 493
Brake Lining and Associated Parts................................................................................................... 493
Removal............................................................................................................................. 493
Brake Lining Inspection............................................................................................................. 494
Installation........................................................................................................................ 494
Drum Brake Adjustment (4ﾗ2 Model)................................................................................................... 495
Servicing The Brake Drum............................................................................................................ 495
Wheel Cylinder Assembly (4ﾗ2 Model)..................................................................................................... 496
Wheel Cylinder Assembly and Associated Parts........................................................................................ 496
Removal............................................................................................................................. 496
Installation........................................................................................................................ 496
Disassembled View................................................................................................................... 497
Disassembly......................................................................................................................... 497
Inspection and Repair............................................................................................................... 497
Reassembly.......................................................................................................................... 497
Main Data and Specifications........................................................................................................ 499
5D1 PARKING BRAKE SYSTEM (4x4 Model)....................................................................................................... 500
Service Precaution...................................................................................................................... 500
General Description..................................................................................................................... 500
Operation............................................................................................................................... 501
Parking Brake Lever and Front Cable..................................................................................................... 502
Parking Brake Lever Assembly and Associated Parts................................................................................... 502
Removal............................................................................................................................. 502
Installation........................................................................................................................ 502
Parking Brake Rear Cable................................................................................................................ 503
Parking Brake Rear Cable and Associated Parts....................................................................................... 503
Removal............................................................................................................................. 504
Installation........................................................................................................................ 504
Inspection and Repair............................................................................................................... 505
Parking Brake Adjustment............................................................................................................ 505
Main Data and Specifications............................................................................................................ 506
5D2 PARKING BRAKE SYSTEM (4x2 Model)....................................................................................................... 507
Service Precaution...................................................................................................................... 507
General Description..................................................................................................................... 507
Parking Brake Lever..................................................................................................................... 508
Parking Brake Lever Assembly and Associated Parts................................................................................... 508
Removal............................................................................................................................. 508
Installation........................................................................................................................ 508
Parking Brake Rear Cable................................................................................................................ 509
Parking Brake Rear Cable and Associated Parts....................................................................................... 509
Removal............................................................................................................................. 510
Installation........................................................................................................................ 510
Parking Brake Adjustment................................................................................................................ 510
Main Data and Specifications............................................................................................................ 511
Sec.6 ENGINE.................................................................................................................................. 512
X22SE 2.2L ENGINE........................................................................................................................... 512
6A ENGINE MECHANICAL (X22SE 2.2L)..................................................................................................... 512
Service Precaution.................................................................................................................. 513
General Description................................................................................................................. 513
Engine Diagnosis.................................................................................................................... 514
Cylinder Head Cover................................................................................................................. 527
Removal......................................................................................................................... 527
Installation.................................................................................................................... 528
Exhaust Manifold.................................................................................................................... 529
Removal......................................................................................................................... 529
Installation.................................................................................................................... 529
Crankshaft Pulley................................................................................................................... 530
Removal......................................................................................................................... 530
Installation.................................................................................................................... 530
Intake Manifold..................................................................................................................... 531
Removal......................................................................................................................... 531
Installation.................................................................................................................... 532
Cylinder Head Assembly.............................................................................................................. 533
Removal......................................................................................................................... 533
Installation.................................................................................................................... 535
Timing Belt......................................................................................................................... 539
Removal......................................................................................................................... 539
Installation.................................................................................................................... 540
Camshaft............................................................................................................................ 543
Removal......................................................................................................................... 543
Installation.................................................................................................................... 544
Engine Assembly..................................................................................................................... 546
Removal......................................................................................................................... 547
Installation.................................................................................................................... 548
Cylinder Head....................................................................................................................... 550
Cylinder Head and Associated Parts.............................................................................................. 550
Disassembly..................................................................................................................... 550
Inspection and Repair........................................................................................................... 551
Reassembly...................................................................................................................... 552
Valve Spring, Valve, Valve Guide.................................................................................................... 553
Valve Spring, Valve, Valve Guide and Associated Parts........................................................................... 553
Disassembly..................................................................................................................... 553
Inspection and Repair........................................................................................................... 554
Valve Seat Insert Replacement................................................................................................... 555
Reassembly...................................................................................................................... 555
Camshaft............................................................................................................................ 556
Camshaft and Associated Parts................................................................................................... 556
Disassembly..................................................................................................................... 556
Reassembly...................................................................................................................... 557
Crankshaft.......................................................................................................................... 558
Crankshaft and Associated Parts................................................................................................. 558
Disassembly..................................................................................................................... 558
Inspection and Repair........................................................................................................... 559
Inspection and Repair........................................................................................................... 560
Reassembly...................................................................................................................... 561
Piston and Connecting Rod........................................................................................................... 564
Piston, Connecting Rod and Associate Parts...................................................................................... 564
Disassembly..................................................................................................................... 564
Inspection and Repair........................................................................................................... 565
Reassembly...................................................................................................................... 567
Cylinder Block...................................................................................................................... 568
Cylinder Block and Associated Parts............................................................................................. 568
Disassembly..................................................................................................................... 569
Inspection and Repair........................................................................................................... 569
Reassembly...................................................................................................................... 570
Cylinder Head Cover................................................................................................................. 571
Cylinder Head Cover and Associated parts........................................................................................ 571
Removal......................................................................................................................... 572
Installation.................................................................................................................... 572
Balance Unit Assembly............................................................................................................... 574
Balance Unit Assembly Associated Parts.......................................................................................... 574
Disassembly..................................................................................................................... 575
Adjustment...................................................................................................................... 575
Reassembly...................................................................................................................... 577
Main Data and Specifications........................................................................................................ 579
6B ENGINE COOLING (X22SE 2.2L)........................................................................................................ 585
Service Precaution.................................................................................................................. 585
General Description................................................................................................................. 586
Diagnosis........................................................................................................................... 588
Draining and Refilling Cooling System............................................................................................... 588
Water Pump.......................................................................................................................... 589
Water Pump and Associated Parts................................................................................................. 589
Removal......................................................................................................................... 589
Inspection...................................................................................................................... 589
Installation.................................................................................................................... 589
Thermostat.......................................................................................................................... 590
Removal......................................................................................................................... 590
Inspection...................................................................................................................... 590
Installation.................................................................................................................... 590
Radiator............................................................................................................................ 591
Radiator and Associated Parts................................................................................................... 591
Removal......................................................................................................................... 591
Inspection...................................................................................................................... 592
Installation.................................................................................................................... 592
Main Data and Specifications........................................................................................................ 593
Special Tool........................................................................................................................ 593
6C ENGINE FUEL (X22SE 2.2L)........................................................................................................... 594
Service Precaution.................................................................................................................. 594
General Description................................................................................................................. 595
Fuel Metering....................................................................................................................... 596
Fuel Filter......................................................................................................................... 597
Fuel Filter and Associated Parts................................................................................................ 597
Removal......................................................................................................................... 597
Inspection...................................................................................................................... 597
Installation.................................................................................................................... 597
Inspection...................................................................................................................... 597
In-Tank Fuel Filter............................................................................................................. 597
Fuel Pump Flow Test............................................................................................................. 598
Fuel Pump........................................................................................................................... 599
Fuel Pump and Associated Parts.................................................................................................. 599
Removal......................................................................................................................... 599
Installation.................................................................................................................... 599
Fuel Tube / Quick-Connector Fittings................................................................................................ 600
Precautions..................................................................................................................... 600
Cautions During Work............................................................................................................ 600
Removal......................................................................................................................... 600
Reuse of Quick-Connector........................................................................................................ 602
Assembling Advice............................................................................................................... 602
Fuel Pump Relay..................................................................................................................... 603
General Description............................................................................................................. 603
Fuel Tank........................................................................................................................... 603
Fuel Tank and Associated Parts.................................................................................................. 603
Removal......................................................................................................................... 604
Installation.................................................................................................................... 604
Fuel Gage Unit...................................................................................................................... 604
Removal and Installation........................................................................................................ 604
Fuel Filler Cap..................................................................................................................... 605
General Description............................................................................................................. 605
Inspection...................................................................................................................... 605
Main Data and Specifications........................................................................................................ 606
Special Tool........................................................................................................................ 606
6D1 ENGINE ELECTRICAL (X22SE 2.2L)..................................................................................................... 607
Service Precaution.................................................................................................................. 607
Battery............................................................................................................................. 608
General Description............................................................................................................. 608
Diagnosis....................................................................................................................... 608
Battery Charging................................................................................................................ 609
Jump Starting................................................................................................................... 609
Battery Removal................................................................................................................. 610
Battery Installation............................................................................................................ 610
Main Data and Specifications........................................................................................................ 611
6D2 IGNITION SYSTEM (X22SE 2.2L)....................................................................................................... 612
Service Precaution.................................................................................................................. 612
General Description................................................................................................................. 612
Diagnosis........................................................................................................................... 612
Ignition Module..................................................................................................................... 613
Removal......................................................................................................................... 613
Installation.................................................................................................................... 613
Spark Plug.......................................................................................................................... 613
Removal......................................................................................................................... 613
Inspection and Repair........................................................................................................... 613
Installation.................................................................................................................... 614
Crankshaft Angle Sensor............................................................................................................. 614
Removal......................................................................................................................... 614
Installation.................................................................................................................... 614
Main Data and Specifications........................................................................................................ 615
6D3 STARTING AND CHARGING SYSTEM (X22SE 2.2L).......................................................................................... 616
Service Precaution.................................................................................................................. 616
Starting System..................................................................................................................... 617
General Description................................................................................................................. 617
Diagnosis........................................................................................................................... 617
Starter............................................................................................................................. 618
Removal......................................................................................................................... 618
Installation.................................................................................................................... 618
Disassembled View............................................................................................................... 619
Inspection and Repair........................................................................................................... 620
Characteristic Test............................................................................................................. 621
Charging System..................................................................................................................... 622
General Description................................................................................................................. 622
General On-Vehicle Inspection....................................................................................................... 622
Generator........................................................................................................................... 623
Removal......................................................................................................................... 623
Inspection...................................................................................................................... 623
Installation.................................................................................................................... 624
Disassembly..................................................................................................................... 624
Inspection and Repair........................................................................................................... 626
Reassembly...................................................................................................................... 628
Main Data and Specifications........................................................................................................ 629
6E1 2.2L ENGINE DRIVEABILITY AND EMISSIONS............................................................................................. 630
SPECIFICATIONS...................................................................................................................... 635
TIGHTENING SPECIFICATIONS....................................................................................................... 635
DIAGRAMS AND SCHEMATICS............................................................................................................. 636
PCM WIRING DIAGRAM (1 of 10).................................................................................................... 636
PCM WIRING DIAGRAM (2 of 10).................................................................................................... 637
PCM WIRING DIAGRAM (3 of 10).................................................................................................... 638
PCM WIRING DIAGRAM (4 of 10).................................................................................................... 639
PCM WIRING DIAGRAM (5 of 10).................................................................................................... 640
PCM WIRING DIAGRAM (6 of 10).................................................................................................... 641
PCM WIRING DIAGRAM (7 of 10).................................................................................................... 642
PCM WIRING DIAGRAM (8 of 10).................................................................................................... 643
PCM WIRING DIAGRAM (9 of 10).................................................................................................... 644
PCM WIRING DIAGRAM (10 of 10)................................................................................................... 645
PCM PINOUTS......................................................................................................................... 646
PCM Pinout Table, 32鳳in Red Connector-Row "A"................................................................................... 646
PCM Pinout Table, 32鳳in Red Connector-Row "B"................................................................................... 647
PCM Pinout Table, 32鳳in White Connector-Row "C"................................................................................. 648
PCM Pinout Table, 32鳳in White Connector-Row "D"................................................................................. 649
PCM Pinout Table, 32鳳in White Connector-Row "E"................................................................................. 650
PCM Pinout Table, 32鳳in White Connector-Row "F"................................................................................. 651
COMPONENT LOCATOR............................................................................................................... 652
Engine Component Locator Table.................................................................................................. 654
Undercarriage Component Locator Table........................................................................................... 654
Fuse And Relay Panel (Underhood Electrical Center).............................................................................. 654
DIAGNOSIS Strategy-Based Diagnostics................................................................................................ 656
DTC Stored...................................................................................................................... 656
No DTC.......................................................................................................................... 656
No Matching Symptom............................................................................................................. 656
Intermittents................................................................................................................... 656
No Trouble Found................................................................................................................ 656
Verifying Vehicle Repair........................................................................................................ 656
GENERAL SERVICE INFORMATION......................................................................................................... 657
OBD II Serviceability Issues.................................................................................................... 657
Emissions Control Information Label............................................................................................. 657
Maintenance Schedule............................................................................................................ 658
Visual/Physical Engine Compartment Inspection................................................................................... 658
Basic Knowledge Of Tools Required............................................................................................... 658
SERIAL DATA COMMUNICATIONS.......................................................................................................... 658
Class II Serial Data Communications............................................................................................. 658
ON-BOARD DIAGNOSTIC (OBD II)........................................................................................................ 658
On-board Diagnostic Tests....................................................................................................... 658
Comprehensive Component Monitor Diagnostic Operation............................................................................ 658
System Status And Drive Cycle For Satisfying Federal Inspection/Maintenance (I/M 240) Regulations............................... 659
Common OBD II Terms............................................................................................................. 659
The Diagnostic Executive........................................................................................................ 660
DTC Types....................................................................................................................... 661
Decimal/Binary/Hexadecimal Conversions.......................................................................................... 662
Verifying Vehicle Repair........................................................................................................ 662
Reading Diagnostic Trouble Codes Using A Tech 2 Scan Tool....................................................................... 662
Tech 2.......................................................................................................................... 663
Tech 2 Features................................................................................................................. 664
Getting Started................................................................................................................. 664
Operating Procedure (Example)................................................................................................... 665
Menu............................................................................................................................ 666
DTC Modes....................................................................................................................... 666
DTC Information Mode............................................................................................................ 666
Miscellaneous Test.............................................................................................................. 667
Lamps Test...................................................................................................................... 667
Relays Test..................................................................................................................... 668
EVAP Test....................................................................................................................... 670
Idle Air Control System Test.................................................................................................... 671
Fuel System Test................................................................................................................ 673
EGR Control Test................................................................................................................ 674
Injector Balance Test........................................................................................................... 675
Plotting Snapshot Graph............................................................................................................. 676
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information).................................................. 677
Flow Chart for Snapshot Replay (Plotting Graph)................................................................................. 678
PRIMARY SYSTEM-BASED DIAGNOSTICS.................................................................................................... 679
Primary System-based Diagnostics................................................................................................ 679
Fuel Control Heated Oxygen Sensors.............................................................................................. 679
HO2S Heater..................................................................................................................... 679
Catalyst Monitor Heated Oxygen Sensors And Diagnostic Operation................................................................. 679
MISFIRE MONITOR DIAGNOSTIC OPERATION................................................................................................ 680
Misfire Counters................................................................................................................ 680
FUEL TRIM SYSTEM MONITOR............................................................................................................ 681
Fuel Trim Cell Diagnostic Weights............................................................................................... 681
ON-BOARD DIAGNOSTIC (OBD II) SYSTEM CHECK........................................................................................... 682
A/C CLUTCH CONTROL CIRCUIT DIAGNOSIS................................................................................................ 685
ELECTRONIC IGNITION SYSTEM DIAGNOSIS................................................................................................ 688
EVAP CANISTER PURGE SOLENOID........................................................................................................ 688
VISUAL CHECK OF THE EVAPORATIVE EMISSION CANISTER................................................................................... 688
IDLE AIR CONTROL (IAC) VALVE........................................................................................................ 688
FUEL SYSTEM PRESSURE TEST........................................................................................................... 688
FUEL METERING SYSTEM CHECK.......................................................................................................... 688
FUEL INJECTOR COIL TEST PROCEDURE AND FUEL INJECTOR BALANCE TEST PROCEDURE.......................................................... 689
POWERTRAIN CONTROL MODULE (PCM) DIAGNOSIS........................................................................................... 694
MULTIPLE PCM INFORMATION SENSOR DTCs SET............................................................................................ 694
EXHAUST GAS RECIRCULATION (EGR) DIAGNOSIS........................................................................................... 698
ENGINE Tech 2 DATA DEFINITIONS AND RANGES........................................................................................... 698
TYPICAL SCAN DATA VALUES............................................................................................................ 701
NO MALFUNCTION INDICATOR LAMP (MIL)................................................................................................. 705
MALFUNCTION INDICATOR LAMP (MIL) ON STEADY.......................................................................................... 708
ENGINE CRANKS BUT WILL NOT RUN...................................................................................................... 710
FUEL SYSTEM ELECTRICAL TEST......................................................................................................... 716
FUEL SYSTEM DIAGNOSIS............................................................................................................... 719
IDLE AIR CONTROL (IAC) SYSTEM CHECK................................................................................................. 724
EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK........................................................................................ 727
MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK....................................................................................... 729
EVAPORATIVE (EVAP) EMISSIONS CANISTER PURGE VALVE SOLENOID CHECK.................................................................... 731
Upshift Lamp System Check (Manual Transmission Only)................................................................................ 734
PCM DIAGNOSTIC TROUBLE CODES........................................................................................................ 737
DIAGNOSTIC TROUBLE CODE (DTC) P0106 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT/RANGE PERFORMANCE PROBLEM.............................. 740
DIAGNOSTIC TROUBLE CODE (DTC) P0107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT LOW INPUT....................................... 743
DIAGNOSTIC TROUBLE CODE (DTC) P0108 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT HIGH INPUT............................................. 746
DIAGNOSTIC TROUBLE CODE (DTC) P0112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW INPUT........................................... 749
DIAGNOSTIC TROUBLE CODE (DTC) P0113 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH INPUT.......................................... 752
DIAGNOSTIC TROUBLE CODE (DTC) P0117 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT LOW INPUT....................................... 755
DIAGNOSTIC TROUBLE CODE (DTC) P0118 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT HIGH INPUT...................................... 758
DIAGNOSTIC TROUBLE CODE (DTC) P0121 THROTTLE POSITION (TP) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM................................. 761
DIAGNOSTIC TROUBLE CODE (DTC) P0122 THROTTLE POSITION (TP) SENSOR CIRCUITLOW INPUT.................................................. 764
DIAGNOSTIC TROUBLE CODE (DTC) P0123 THROTTLE POSITION (TP) SENSOR CIRCUIT HIGH INPUT................................................ 767
DIAGNOSTIC TROUBLE CODE (DTC) P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL................................... 770
DIAGNOSTIC TROUBLE CODE (DTC) P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)................................................. 773
DIAGNOSTIC TROUBLE CODE (DTC) P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)................................................ 776
DIAGNOSTIC TROUBLE CODE (DTC) P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)............................................... 779
DIAGNOSTIC TROUBLE CODE (DTC) P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)........................................ 782
DIAGNOSTIC TROUBLE CODE (DTC) P0135 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 1).......................................... 785
DIAGNOSTIC TROUBLE CODE (DTC) P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)................................................. 788
DIAGNOSTIC TROUBLE CODE (DTC) P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)................................................ 791
DIAGNOSTIC TROUBLE CODE (DTC) P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 2)........................................ 794
DIAGNOSTIC TROUBLE CODE (DTC) P0141 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 2).......................................... 797
DIAGNOSTIC TROUBLE CODE (DTC) P0171 SYSTEM TOO LEAN (BANK 1)........................................................................ 800
DIAGNOSTIC TROUBLE CODE (DTC) P0172 SYSTEM TOO RICH (BANK 1)........................................................................ 804
DIAGNOSTIC TROUBLE CODE (DTC) P0201 INJECTOR CIRCUIT MALFUNCTION-CYLINDER 1......................................................... 808
DIAGNOSTIC TROUBLE CODE (DTC) P0202 INJECTOR CIRCUIT MALFUNCTION-CYLINDER 2......................................................... 811
DIAGNOSTIC TROUBLE CODE (DTC) P0203 INJECTOR CIRCUIT MALFUNCTION-CYLINDER 3......................................................... 814
DIAGNOSTIC TROUBLE CODE (DTC) P0204 INJECTOR CIRCUIT MALFUNCTION-CYLINDER 4......................................................... 817
DIAGNOSTIC TROUBLE CODE (DTC) P0300 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED....................................................... 820
DIAGNOSTIC TROUBLE CODE (DTC) P0301 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED....................................................... 824
DIAGNOSTIC TROUBLE CODE (DTC) P0302 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED....................................................... 828
DIAGNOSTIC TROUBLE CODE (DTC) P0303 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED....................................................... 832
DIAGNOSTIC TROUBLE CODE (DTC) P0304 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED....................................................... 836
DIAGNOSTIC TROUBLE CODE (DTC) P0325 KNOCK SENSOR (KS) CIRCUIT MALFUNCTION........................................................... 840
DIAGNOSTIC TROUBLE CODE (DTC) P0327 KNOCK SENSOR (KS) CIRCUIT LOW INPUT............................................................. 843
DIAGNOSTIC TROUBLE CODE (DTC) P0336 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT RANGE/PERFORMANCE...................................... 846
DIAGNOSTIC TROUBLE CODE (DTC) P0337 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT LOW INPUT.............................................. 848
DIAGNOSTIC TROUBLE CODE (DTC) P0341 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT RANGE/PERFORMANCE........................................ 851
DIAGNOSTIC TROUBLE CODE (DTC) P0342 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT LOW INPUT................................................ 854
DIAGNOSTIC TROUBLE CODE (DTC) P0351 IGNITION COIL "A" PRIMARY/SECONDARY CIRCUIT MALFUNCTION......................................... 857
DIAGNOSTIC TROUBLE CODE (DTC) P0352 IGNITION COIL "B" PRIMARY/SECONDARY CIRCUIT MALFUNCTION......................................... 859
DIAGNOSTIC TROUBLE CODE (DTC) P0401 EXHAUST GAS RECIRCULATION (EGR) FLOW INSUFFICIENT DETECTED...................................... 861
DIAGNOSTIC TROUBLE CODE (DTC) P0402 EXHAUST GAS RECIRCULATION (EGR) EXCESSIVE FLOW DETECTED......................................... 864
DIAGNOSTIC TROUBLE CODE (DTC) P0404 EXHAUST GAS RECIRCULATION (EGR) CIRCUIT RANGE/PERFORMANCE....................................... 866
DIAGNOSTIC TROUBLE CODE (DTC) P0405 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT LOW.............................................. 870
DIAGNOSTIC TROUBLE CODE (DTC) P0406 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT HIGH............................................. 873
DIAGNOSTIC TROUBLE CODE (DTC) P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD...................................................... 877
DIAGNOSTIC TROUBLE CODE (DTC) P0440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM MALFUNCTION.......................................... 880
DIAGNOSTIC TROUBLE CODE (DTC) P0442 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM SMALL LEAK DETECTED.................................. 885
DIAGNOSTIC TROUBLE CODE (DTC) P0443 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION.............. 889
DIAGNOSTIC TROUBLE CODE (DTC) P0446 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT CONTROL CIRCUIT MALFUNCTION..................... 892
DIAGNOSTIC TROUBLE CODE (DTC) P0449 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT VALVE/SOLENOID CIRCUIT MALFUNCTION.............. 896
DIAGNOSTIC TROUBLE CODE (DTC) P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE..................................................... 899
DIAGNOSTIC TROUBLE CODE (DTC) P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT............................................................. 901
DIAGNOSTIC TROUBLE CODE (DTC) P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT............................................................ 903
DIAGNOSTIC TROUBLE CODE (DTC) P0480 COOLING FAN 1 CONTROL CIRCUIT MALFUNCTION....................................................... 905
DIAGNOSTIC TROUBLE CODE (DTC) P0481 COOLING FAN 2 CONTROL CIRCUIT MALFUNCTION....................................................... 908
DIAGNOSTIC TROUBLE CODE (DTC) P0502 VEHICLE SPEED SENSOR (VSS) CIRCUIT LOW INPUT.................................................... 911
DIAGNOSTIC TROUBLE CODE (DTC) P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED..................................................... 913
DIAGNOSTIC TROUBLE CODE (DTC) P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED.................................................... 916
DIAGNOSTIC TROUBLE CODE (DTC) P0532 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT LOW INPUT............................................... 919
DIAGNOSTIC TROUBLE CODE (DTC) P0533 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT HIGH INPUT.............................................. 922
DIAGNOSTIC TROUBLE CODE (DTC) P0562 SYSTEM VOLTAGE LOW.............................................................................. 925
DIAGNOSTIC TROUBLE CODE (DTC) P0563 SYSTEM VOLTAGE HIGH............................................................................. 927
DIAGNOSTIC TROUBLE CODE (DTC) P0601 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR.................................................. 929
DIAGNOSTIC TROUBLE CODE (DTC) P1106 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE....................... 931
DIAGNOSTIC TROUBLE CODE (DTC) P1107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE........................ 933
DIAGNOSTIC TROUBLE CODE (DTC) P1111 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE........................... 935
DIAGNOSTIC TROUBLE CODE (DTC) P1112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE............................ 938
DIAGNOSTIC TROUBLE CODE (DTC) P1114 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE........................ 940
DIAGNOSTIC TROUBLE CODE (DTC) P1115 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE....................... 942
DIAGNOSTIC TROUBLE CODE (DTC) P1121 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE................................. 945
DIAGNOSTIC TROUBLE CODE (DTC) P1122 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE.................................. 947
DIAGNOSTIC TROUBLE CODE (DTC) P1133 O2 SENSOR INSUFFICIENT SWITCHING (BANK 1 SENSOR 1).............................................. 949
DIAGNOSTIC TROUBLE CODE (DTC) P1134 O2 SENSOR TRANSITION TIME RATIO (BANK 1 SENSOR 1)............................................... 952
DIAGNOSTIC TROUBLE CODE (DTC) P1171 FUEL SYSTEM LEAN DURING ACCELERATION............................................................ 955
DIAGNOSTIC TROUBLE CODE (DTC) P1336 CRANKSHAFT POSITION SENSOR (CKP) SYSTEM VARIATION NOT LEARNED................................... 958
DIAGNOSTIC TROUBLE CODE (DTC) P1380 ABS ROUGH ROAD SYSTEM FAULT..................................................................... 961
DIAGNOSTIC TROUBLE CODE (DTC) P1381 ABS ROUGH ROAD CLASS 2 SERIAL DATA FAULT........................................................ 963
DIAGNOSTIC TROUBLE CODE (DTC) 1404 EXHAUST GAS RECIRCULATION (EGR) CLOSED VALVE..................................................... 966
DIAGNOSTIC TROUBLE CODE (DTC) P1441 EVAPORATIVE EMISSION (EVAP) SYSTEM FLOW DURING NON-PURGE........................................ 969
DIAGNOSTIC TROUBLE CODE (DTC) P1546 A/C COMPRESSOR CLUTCH OUTPUT CIRCUIT MALFUNCTION................................................ 972
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset............................................................................ 975
DIAGNOSTIC TROUBLE CODE (DTC) P1627 PCM A/D CONVERSION MALFUNCTION.................................................................. 977
DIAGNOSTIC TROUBLE CODE (DTC) P1635 5 VOLT REFERENCE VOLTAGE CIRCUIT MALFUNCTION.................................................... 979
DIAGNOSTIC TROUBLE CODE (DTC) P1640 ODM OUTPUT CIRCUIT FAULT........................................................................ 981
SYMPTOM DIAGNOSIS................................................................................................................... 984
DEFAULT MATRIX TABLE................................................................................................................ 1007
Camshaft Position (CMP) Sensor...................................................................................................... 1010
Crankshaft Position (CKP) Sensor.................................................................................................... 1011
EEPROM.............................................................................................................................. 1013
Engine Coolant Temperature (ECT) Sensor............................................................................................. 1013
Heated Oxygen Sensor (HO2S)......................................................................................................... 1014
Intake Air Temperature (IAT) Sensor................................................................................................. 1015
Manifold Absolute Pressure (MAP) Sensor............................................................................................. 1016
Malfunction Indicator Lamp (MIL).................................................................................................... 1017
Powertrain Control Module (PCM)..................................................................................................... 1017
Throttle Position (TP) Sensor....................................................................................................... 1020
Vehicle Speed Sensor (VSS).......................................................................................................... 1021
Air Filter.......................................................................................................................... 1022
Idle Air Control (IAC) Valve........................................................................................................ 1023
Intake Air Duct..................................................................................................................... 1024
Knock Sensor........................................................................................................................ 1026
Oil Pressure Switch................................................................................................................. 1027
FUEL METERING SYSTEM Accelerator Cable Assembly..................................................................................... 1027
Cable Adjustment Section............................................................................................................ 1029
Fuel Filler Cap..................................................................................................................... 1030
Fuel Filter......................................................................................................................... 1030
Fuel Injectors...................................................................................................................... 1032
Fuel Pressure Regulator............................................................................................................. 1033
Fuel Pump Assembly.................................................................................................................. 1035
Fuel Pump Relay..................................................................................................................... 1037
Fuel Rail Assembly.................................................................................................................. 1037
Fuel Tank........................................................................................................................... 1039
Throttle body (TB).................................................................................................................. 1040
ELECTRONIC IGNITION SYSTEM Ignition Control Module (ICM)............................................................................ 1042
Ignition Coil....................................................................................................................... 1042
Spark Plugs......................................................................................................................... 1043
Spark Plug Cables................................................................................................................... 1044
EMISSIONS Catalytic Converter....................................................................................................... 1045
Air Conditioning Relay.............................................................................................................. 1045
Ignition Timing Adjustment.......................................................................................................... 1045
EVAP Canister Hoses................................................................................................................. 1045
EVAP Canister....................................................................................................................... 1045
EVAP Canister Vent Solenoid......................................................................................................... 1046
EVAP Canister Purge Valve Solenoid.................................................................................................. 1046
Linear Exhaust Gas Recirculation (EGR) Valve........................................................................................ 1047
Wiring and Connectors............................................................................................................... 1049
PCM Connectors And Terminals........................................................................................................ 1049
Connectors And Terminals............................................................................................................ 1049
Wire Harness Repair: Twisted Shielded Cable......................................................................................... 1049
Twisted Leads....................................................................................................................... 1050
Weather-Pack Connector.............................................................................................................. 1051
Com-Pack III........................................................................................................................ 1053
Metri-Pack.......................................................................................................................... 1053
GENERAL DESCRIPTION-PCM AND SENSORS................................................................................................. 1054
58X Reference PCM Input......................................................................................................... 1054
A/C Request Signal.............................................................................................................. 1054
Crankshaft Position (CKP) Sensor................................................................................................ 1054
Camshaft Position (CMP) Sensor And Signal....................................................................................... 1054
Engine Coolant Temperature (ECT) Sensor......................................................................................... 1054
Electrically Erasable Programmable Read Only Memory (EEPROM).................................................................... 1055
Fuel Control Heated Oxygen Sensor (Pre Catalyst)................................................................................ 1055
Catalyst Monitor Heated Oxygen Sensor (Post Catalyst)........................................................................... 1055
Intake Air Temperature (IAT) Sensor............................................................................................. 1056
Linear Exhaust Gas Recirculation (EGR) Control.................................................................................. 1056
Manifold Absolute Pressure (MAP) Sensor......................................................................................... 1056
Powertrain Control Module (PCM)................................................................................................. 1057
PCM Function.................................................................................................................... 1057
PCM Components.................................................................................................................. 1057
PCM Voltage Description......................................................................................................... 1057
PCM Inputs/Outputs.............................................................................................................. 1057
PCM Service Precautions......................................................................................................... 1058
Reprogramming the PCM........................................................................................................... 1058
Tooth Error Correction (TEC) Service Bay Guidelines............................................................................. 1058
Throttle Position (TP) Sensor................................................................................................... 1059
Transmission Range Switch....................................................................................................... 1059
Vehicle Speed Sensor (VSS)...................................................................................................... 1059
Use of Circuit Testing Tools.................................................................................................... 1060
Aftermarket Electrical And Vacuum Equipment..................................................................................... 1060
Electrostatic Discharge Damage.................................................................................................. 1060
Upshift Lamp.................................................................................................................... 1060
GENERAL DESCRIPTION-AIR INDUCTION................................................................................................... 1060
Air Induction System............................................................................................................ 1060
GENERAL DESCRIPTION-FUEL METERING................................................................................................... 1061
Acceleration Mode............................................................................................................... 1061
Accelerator Controls............................................................................................................ 1061
Battery Voltage Correction Mode................................................................................................. 1061
CMP Signal...................................................................................................................... 1061
Clear Flood Mode................................................................................................................ 1061
Deceleration Fuel Cutoff (DFCO) Mode............................................................................................ 1061
Engine Speed/Vehicle Speed/ Fuel Disable Mode................................................................................... 1061
Fuel Cutoff Mode................................................................................................................ 1061
Fuel Injector................................................................................................................... 1061
Fuel Metering System Components................................................................................................. 1062
Basic System Operation.......................................................................................................... 1062
Fuel Metering System Purpose.................................................................................................... 1062
Fuel Pressure Regulator......................................................................................................... 1062
Fuel Pump Electrical Circuit.................................................................................................... 1062
Fuel Rail....................................................................................................................... 1062
Idle Air Control (IAC) Valve.................................................................................................... 1063
Run Mode........................................................................................................................ 1063
Starting Mode................................................................................................................... 1063
Throttle Body Unit.............................................................................................................. 1063
GENERAL DESCRIPTION-ELECTRONIC IGNITION SYSTEM...................................................................................... 1064
Camshaft Position (CMP) Sensor.................................................................................................. 1064
Crankshaft Position (CKP) Sensor................................................................................................ 1064
Electronic Ignition............................................................................................................. 1064
Ignition Coils.................................................................................................................. 1064
Ignition Control................................................................................................................ 1064
Ignition Control Module (ICM)................................................................................................... 1065
Ignition Control PCM Output..................................................................................................... 1065
Powertrain Control Module (PCM)................................................................................................. 1065
Spark Plug...................................................................................................................... 1066
A/C CLUTCH DIAGNOSIS................................................................................................................ 1067
A/C Clutch Circuit Operation.................................................................................................... 1067
A/C Clutch Circuit Purpose...................................................................................................... 1067
A/C Request Signal.............................................................................................................. 1067
GENERAL DESCRIPTION-EVAPORATIVE EMISSION (EVAP) SYSTEM.............................................................................. 1068
EVAP Emission Control System Purpose............................................................................................ 1068
EVAP Emission Control System Operation.......................................................................................... 1068
Enhanced Evaporative Emission Control System.................................................................................... 1068
System Fault Detection.......................................................................................................... 1069
GENERAL DESCRIPTION-EXHAUST GAS RECIRCULATION (EGR) SYSTEM.......................................................................... 1069
EGR Purpose..................................................................................................................... 1069
Linear EGR Valve................................................................................................................ 1069
Linear EGR Control.............................................................................................................. 1069
Linear EGR Valve Operation And Results Of Incorrect Operation................................................................... 1070
EGR Pintle Position Sensor...................................................................................................... 1070
GENERAL DESCRIPTION-POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM..................................................................... 1070
Crankcase Ventilation System Purpose............................................................................................ 1070
SPECIAL TOOLS....................................................................................................................... 1071
6F ENGINE EXHAUST (X22SE 2.2L)........................................................................................................ 1073
Service Precaution.................................................................................................................. 1073
General Description................................................................................................................. 1074
Front Exhaust Pipe.................................................................................................................. 1075
Front Exhaust Pipe and Associated Parts......................................................................................... 1075
Removal......................................................................................................................... 1075
Installation.................................................................................................................... 1075
Exhaust Silencer.................................................................................................................... 1076
Exhaust Silencer and Associated Parts........................................................................................... 1076
Removal......................................................................................................................... 1076
Installation.................................................................................................................... 1076
Rear Exhaust pipe................................................................................................................... 1077
Rear Exhaust pipe and Associated Parts.......................................................................................... 1077
Removal......................................................................................................................... 1077
Installation.................................................................................................................... 1077
Main Data and Specifications........................................................................................................ 1078
6G ENGINE LUBRICATION (X22SE 2.2L).................................................................................................... 1079
Service Precaution.................................................................................................................. 1079
General Description................................................................................................................. 1080
Oil Pump............................................................................................................................ 1081
Oil Pump and Associated Parts................................................................................................... 1081
Disassembly..................................................................................................................... 1082
Inspection and Repair........................................................................................................... 1082
Reassembly...................................................................................................................... 1082
6H ENGINE SPEED CONTROL SYSTEM (X22SE 2.2L)........................................................................................... 1083
Service Precaution.................................................................................................................. 1083
Accelerator Pedal Control Cable..................................................................................................... 1084
Removal......................................................................................................................... 1084
Inspection...................................................................................................................... 1084
Installation.................................................................................................................... 1084
Accelerator Pedal................................................................................................................... 1085
Accelerator Pedal and Associated Parts.......................................................................................... 1085
Removal......................................................................................................................... 1085
Installation.................................................................................................................... 1085
6J INDUCTION (X22SE 2.2L).............................................................................................................. 1086
Service Precaution.................................................................................................................. 1086
Air Cleaner Filter.................................................................................................................. 1087
Removal......................................................................................................................... 1087
Inspection...................................................................................................................... 1087
Installation.................................................................................................................... 1087
6VD1 3.2L ENGINE............................................................................................................................ 1088
6A ENGINE MECHANICAL (6VD1 3.2L)...................................................................................................... 1088
Service Precaution.................................................................................................................. 1089
General Description................................................................................................................. 1090
Engine Diagnosis.................................................................................................................... 1091
Cylinder Head Cover LH.............................................................................................................. 1106
Removal......................................................................................................................... 1106
Installation.................................................................................................................... 1107
Cylinder Head Cover RH.............................................................................................................. 1108
Removal......................................................................................................................... 1108
Installation.................................................................................................................... 1108
Common Chamber...................................................................................................................... 1109
Removal......................................................................................................................... 1109
Installation.................................................................................................................... 1109
Exhaust Manifold LH................................................................................................................. 1111
Removal......................................................................................................................... 1111
Installation.................................................................................................................... 1111
Exhaust Manifold RH................................................................................................................. 1112
Removal......................................................................................................................... 1112
Installation.................................................................................................................... 1112
Crankshaft Pulley................................................................................................................... 1113
Removal......................................................................................................................... 1113
Installation.................................................................................................................... 1113
Timing Belt......................................................................................................................... 1114
Removal......................................................................................................................... 1114
Installation.................................................................................................................... 1115
Camshaft............................................................................................................................ 1119
Removal......................................................................................................................... 1119
Installation.................................................................................................................... 1120
Cylinder Head....................................................................................................................... 1123
Removal......................................................................................................................... 1123
Installation.................................................................................................................... 1123
Valve Stem Oil Controller , Valve Spring and Valve Guide............................................................................ 1125
Removal......................................................................................................................... 1125
Installation.................................................................................................................... 1125
Piston, Piston Ring and Connecting Rod.............................................................................................. 1126
Removal......................................................................................................................... 1126
Installation.................................................................................................................... 1127
Crankshaft and Main Bearings........................................................................................................ 1128
Removal......................................................................................................................... 1128
Installation.................................................................................................................... 1129
Rear Oil Seal....................................................................................................................... 1133
Removal......................................................................................................................... 1133
Installation.................................................................................................................... 1133
Engine Assembly..................................................................................................................... 1134
Removal......................................................................................................................... 1134
Installation.................................................................................................................... 1134
Cylinder Head....................................................................................................................... 1138
Cylinder Head and Associated Parts.............................................................................................. 1138
Disassembly..................................................................................................................... 1138
Clean........................................................................................................................... 1139
Inspection and Repair........................................................................................................... 1139
Reassembly...................................................................................................................... 1140
Valve Spring, Oil Controller, Valve, Valve Guide.................................................................................... 1142
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts........................................................... 1142
Disassembly..................................................................................................................... 1142
Inspection and Repair........................................................................................................... 1143
Reassembly...................................................................................................................... 1146
Camshaft............................................................................................................................ 1149
Camshaft and Associated Parts................................................................................................... 1149
Disassembly..................................................................................................................... 1149
Inspection and Repair........................................................................................................... 1150
Reassembly...................................................................................................................... 1152
Crankshaft.......................................................................................................................... 1155
Crankshaft and Associated Parts................................................................................................. 1155
Disassembly..................................................................................................................... 1155
Inspection and Repair........................................................................................................... 1156
Inspection and Repair........................................................................................................... 1158
Reassembly...................................................................................................................... 1159
Piston and Connecting Rod........................................................................................................... 1163
Piston, Connecting Rod and Associate Parts...................................................................................... 1163
Disassembly..................................................................................................................... 1163
Inspection and Repair........................................................................................................... 1164
Reassembly...................................................................................................................... 1168
Cylinder Block...................................................................................................................... 1170
Cylinder Block and Associated Parts............................................................................................. 1170
Disassembly..................................................................................................................... 1170
Inspection and Repair........................................................................................................... 1171
Reassembly...................................................................................................................... 1172
Main Data and Specification......................................................................................................... 1175
Special Tool........................................................................................................................ 1181
6B ENGINE COOLING (6VD1 3.2L)......................................................................................................... 1183
Service Precaution.................................................................................................................. 1183
General Description................................................................................................................. 1184
Diagnosis........................................................................................................................... 1186
Draining and Refilling Cooling System............................................................................................... 1187
Water Pump.......................................................................................................................... 1188
Water Pump and Associated Parts................................................................................................. 1188
Removal......................................................................................................................... 1188
Inspection...................................................................................................................... 1188
Installation.................................................................................................................... 1188
Thermostat.......................................................................................................................... 1189
Thermostat and Associated Parts................................................................................................. 1189
Removal......................................................................................................................... 1189
Inspection...................................................................................................................... 1189
Installation.................................................................................................................... 1189
Radiator............................................................................................................................ 1190
Radiator and Associated Parts................................................................................................... 1190
Removal......................................................................................................................... 1190
Inspection...................................................................................................................... 1191
Installation.................................................................................................................... 1192
Drive Belt and Cooling Fan.......................................................................................................... 1193
Drive Belt and Associated Parts................................................................................................. 1193
Inspection...................................................................................................................... 1193
Installation.................................................................................................................... 1193
Main Data and Specifications........................................................................................................ 1194
Special Tool........................................................................................................................ 1195
6C ENGINE FUEL........................................................................................................................ 1196
Service Precaution.................................................................................................................. 1196
General Description................................................................................................................. 1197
Fuel Metering....................................................................................................................... 1198
Fuel Filter......................................................................................................................... 1199
Removal......................................................................................................................... 1199
Inspection...................................................................................................................... 1199
Installation.................................................................................................................... 1199
Inspection...................................................................................................................... 1200
In-Tank Fuel Filter............................................................................................................. 1200
Fuel Pump Flow Test............................................................................................................. 1200
Fuel Pump........................................................................................................................... 1201
Fuel Pump and Associated Parts.................................................................................................. 1201
Removal......................................................................................................................... 1201
Installation.................................................................................................................... 1201
Fuel Tube / Quick ・Connector Fittings............................................................................................... 1202
Precautions..................................................................................................................... 1202
Cautions During Work............................................................................................................ 1202
Removal......................................................................................................................... 1202
Reuse of Quick-Connector........................................................................................................ 1204
Assembling Advice............................................................................................................... 1204
Fuel Pump Relay..................................................................................................................... 1205
General Description............................................................................................................. 1205
Fuel Tank........................................................................................................................... 1205
Fuel Tank and Associated Parts.................................................................................................. 1205
Removal......................................................................................................................... 1206
Installation.................................................................................................................... 1206
Fuel Gauge Unit..................................................................................................................... 1206
Removal and Installation........................................................................................................ 1206
Fuel Filler Cap..................................................................................................................... 1207
General Description............................................................................................................. 1207
Inspection...................................................................................................................... 1207
Main Data and Specifications........................................................................................................ 1208
6D1 ENGINE ELECTRICAL (6VD1 3.2L)...................................................................................................... 1209
Service Precaution.................................................................................................................. 1209
Battery............................................................................................................................. 1210
General Description................................................................................................................. 1210
Diagnosis........................................................................................................................... 1210
Battery Charging................................................................................................................ 1211
Jump Starting....................................................................................................................... 1211
Battery Removal..................................................................................................................... 1212
Battery Installation................................................................................................................ 1212
Main Data and Specifications........................................................................................................ 1213
6D2 IGNITION SYSTEM (6VD1 3.2L)........................................................................................................ 1214
Service Precaution.................................................................................................................. 1214
General Description................................................................................................................. 1215
Diagnosis........................................................................................................................... 1215
Ignition Coil....................................................................................................................... 1216
Removal......................................................................................................................... 1216
Inspection and Repair........................................................................................................... 1216
Installation.................................................................................................................... 1216
Spark Plug.......................................................................................................................... 1217
Removal......................................................................................................................... 1217
Inspection and Repair........................................................................................................... 1217
Installation.................................................................................................................... 1217
Crankshaft Angle Sensor............................................................................................................. 1218
Removal......................................................................................................................... 1218
Installation.................................................................................................................... 1218
Main Data and Specifications........................................................................................................ 1219
6D3 STARTING AND CHARGING SYSTEM (6VD1 3.2L)........................................................................................... 1220
Service Precaution.................................................................................................................. 1220
Starting System..................................................................................................................... 1221
General Description................................................................................................................. 1221
Diagnosis........................................................................................................................... 1223
Starter............................................................................................................................. 1224
Removal......................................................................................................................... 1224
Installation.................................................................................................................... 1224
Disassembled View............................................................................................................... 1225
Disassembly..................................................................................................................... 1226
Inspection and Repair........................................................................................................... 1228
Reassembly...................................................................................................................... 1232
Main Data and Specifications.................................................................................................... 1234
Charging System..................................................................................................................... 1237
General Description................................................................................................................. 1237
General On-Vehicle Inspection....................................................................................................... 1237
Generator........................................................................................................................... 1238
Removal......................................................................................................................... 1238
Inspection...................................................................................................................... 1238
Installation.................................................................................................................... 1239
Disassembled View............................................................................................................... 1239
Disassembly..................................................................................................................... 1240
Inspection and Repair........................................................................................................... 1241
Reassembly...................................................................................................................... 1243
Bench Test...................................................................................................................... 1244
Main Data and Specifications.................................................................................................... 1245
6E2 3.2L ENGINE DRIVEABILITY AND EMISSIONS............................................................................................. 1246
Specification....................................................................................................................... 1251
Tightening Specifications....................................................................................................... 1251
Diagrams and Schematics............................................................................................................. 1252
PCM Wiring Diagram (1 of 8)..................................................................................................... 1252
PCM Wiring Diagram (2 of 8)..................................................................................................... 1253
PCM Wiring Diagram (3 of 8)..................................................................................................... 1254
PCM Wiring Diagram (4 of 8)..................................................................................................... 1255
PCM Wiring Diagram (5 of 8)..................................................................................................... 1256
PCM Wiring Diagram (6 of 8)..................................................................................................... 1257
PCM Wiring Diagram (7 of 8)..................................................................................................... 1258
PCM Wiring Diagram (8 of 8)..................................................................................................... 1259
PCM Pinouts......................................................................................................................... 1260
PCM Pinout Table, 32-Way Red Connector-Row "A".................................................................................. 1260
PCM Pinout Table, 32-Way Red Connector-Row "B".................................................................................. 1261
PCM Pinout Table, 32-Way White Connector-Row "C"................................................................................ 1262
PCM Pinout Table, 32-Way White Connector-Row "D"................................................................................ 1263
PCM Pinout Table, 32-Way Blue Connector-Row "E"................................................................................. 1264
PCM Pinout Table, 32-Way Blue Connector-Row "F"................................................................................. 1265
Component Locators.................................................................................................................. 1266
Engine Component Locator........................................................................................................ 1266
Engine Component Locator Table.................................................................................................. 1267
Undercarriage Component Locator................................................................................................. 1268
Undercarriage Component Locator Table........................................................................................... 1268
Sensors and Miscellaneous Component Locators.................................................................................... 1269
Fuse and Relay Panel (Underhood Electrical Center).................................................................................. 1272
Diagnosis........................................................................................................................... 1273
Strategy-Based Diagnostics...................................................................................................... 1273
DTC Stored...................................................................................................................... 1273
No DTC.......................................................................................................................... 1273
No Matching Symptom............................................................................................................. 1273
Intermittents................................................................................................................... 1273
No Trouble Found................................................................................................................ 1273
Verifying Vehicle Repair........................................................................................................ 1273
General Service Information......................................................................................................... 1274
OBD II Serviceability Issues.................................................................................................... 1274
Emissions Control Information Label............................................................................................. 1274
Maitenance Schedule............................................................................................................. 1275
Visual/Physical Engine Compartment Inspection................................................................................... 1275
Basic Knowledge of Tools Required............................................................................................... 1275
Seral Data Communications........................................................................................................... 1275
Class II Serial Data Communications............................................................................................. 1275
On-Board Diagnostic (OBD II)........................................................................................................ 1275
On-Board Diagnostic Tests....................................................................................................... 1275
Comprehensive Component Monitor Diagnostic Operation............................................................................ 1275
System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations............................... 1276
Common OBD II Terms............................................................................................................. 1276
The Diagnostic Executive........................................................................................................ 1277
DTC Types....................................................................................................................... 1278
Decimal/Binary/Hexadecimal Conversions.......................................................................................... 1279
Verifying Vehicle Repair........................................................................................................ 1279
Reading Diagnostic Trouble Codes Using the TECH 2 Scan Tool..................................................................... 1279
Tech 2.......................................................................................................................... 1280
Tech 2 Features................................................................................................................. 1281
Getting Started................................................................................................................. 1281
Operating Procedure (For Example)............................................................................................... 1282
Menu............................................................................................................................ 1283
DTC Modes....................................................................................................................... 1283
DTC Information Mode............................................................................................................ 1283
Miscellaneous Test.............................................................................................................. 1284
Lamps Test...................................................................................................................... 1284
Relays Test..................................................................................................................... 1285
EVAP Test....................................................................................................................... 1286
Idle Air Control System Test.................................................................................................... 1288
Fuel System Test................................................................................................................ 1289
EGR Control Test................................................................................................................ 1291
Variable Intake Manifold Solenoid Test.......................................................................................... 1291
Injector Balance Test........................................................................................................... 1292
Plotting Snapshot Graph............................................................................................................. 1293
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information).................................................. 1294
Flow Chart for Snapshot Replay (Plotting Graph)................................................................................. 1295
To upload Snapshots to a PC and Download Diagnostic Software from a CD ROM Disk................................................. 1296
Primary System-Based Diagnostics.................................................................................................... 1296
Primary System-Based Diagnostics................................................................................................ 1296
Fuel Control Heated Oxygen Sensors.............................................................................................. 1296
HO2S Heater..................................................................................................................... 1296
Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation................................................................. 1296
Misfire Monitor Diagnostic Operation................................................................................................ 1297
Misfire Monitor Diagnostic Operation............................................................................................ 1297
Misfire Counters................................................................................................................ 1297
Fuel Trim System Monitor Diagnostic Operation....................................................................................... 1298
Fuel Trim System Monitor Diagnostic Operation................................................................................... 1298
Fuel Trim Cell Diagnostic Weights............................................................................................... 1298
On-Board Diagnostic (OBD II) System Check........................................................................................... 1299
A/C Clutch Control Circuit Diagnosis................................................................................................ 1302
Electronic Ignition System Diagnosis................................................................................................ 1308
EVAP Canister Purge Solenoid........................................................................................................ 1308
Visual Check of The Evaporative Emission Canister................................................................................... 1308
Fuel Metering System Check.......................................................................................................... 1308
Idle Air Control (IAC) Valve........................................................................................................ 1308
Fuel System Pressure Test........................................................................................................... 1308
Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure.......................................................... 1308
Knock Sensor Diagnosis.............................................................................................................. 1313
Powertrain Control Module (PCM) Diagnosis........................................................................................... 1313
Multiple PCM Information Sensor DTCS Set............................................................................................ 1313
Multiple PCM Information Sensor DTCs Set........................................................................................... 1314
Exhaust Gas Recirculation (EGR) Diagnosis........................................................................................... 1316
Engine Tech 2 Data Definitions and Ranges........................................................................................... 1316
Typical Scan Data Values............................................................................................................ 1319
No Malfunction Indicator Lamp (MIL)................................................................................................. 1326
Malfunction Indicator Lamp (MIL) "ON" Steady........................................................................................ 1329
Engine Cranks But Will Not Run...................................................................................................... 1332
Fuel System Electrical Test......................................................................................................... 1337
Fuel System Diagnosis............................................................................................................... 1340
Idle Air Control (IAC) System Check................................................................................................. 1345
Knock Sensor (KS) System Check (Engine Knock, Poor Performance, or Poor Economy).................................................... 1348
Exhaust Gas Recirculation (EGR) System Check........................................................................................ 1350
Manifold Absolute Pressure (MAP) Output Check....................................................................................... 1352
Evaporative (EVAP) Emissions Canister Purge Valve Check............................................................................. 1354
Up-Shift Lamp System Check.......................................................................................................... 1357
PCM Diagnostic Trouble Codes........................................................................................................ 1360
Diagnostic Trouble Code (DTC) P0101 MAF System Performance.......................................................................... 1364
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency................................................................ 1367
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency............................................................... 1370
Diagnostic Trouble Code (DTC) P0106 MAP System Performance.......................................................................... 1373
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage.................................................................. 1376
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit Hight Voltage................................................................ 1379
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage.................................................................. 1382
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage................................................................. 1385
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage.................................................................. 1388
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage................................................................. 1391
Diagnostic Trouble Code (DTC) P0121 TP System Performance........................................................................... 1394
Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage................................................................... 1397
Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage.................................................................. 1400
Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control.................................................. 1403
Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1........................................................ 1406
Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1....................................................... 1409
Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1.............................................................. 1412
Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1.............................................. 1416
Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1............................................................. 1419
Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2........................................................ 1422
Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2....................................................... 1425
Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2............................................... 1428
Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2............................................................. 1431
Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1........................................................ 1434
Diagnostic Trouble Code (DTC) P0152 HO2S Circuit High Voltage Bank 2 Sensor 1....................................................... 1437
Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1.............................................................. 1440
Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1.............................................. 1444
Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Bank 2 Sensor 1............................................................. 1447
Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2........................................................ 1450
Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2....................................................... 1453
Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2.............................................. 1456
Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2............................................................. 1459
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Too Lean Bank 1................................................................ 1462
Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1.................................................................... 1466
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2.................................................................... 1470
Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2.................................................................... 1474
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit...................................................................... 1478
Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit...................................................................... 1481
Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit...................................................................... 1484
Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit...................................................................... 1487
Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit...................................................................... 1490
Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit...................................................................... 1493
Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected......................................................................... 1496
Diagnostic Trouble Code (DTC) P0301 Cylinder 1 Misfire Detected..................................................................... 1500
Diagnostic Trouble Code (DTC) P0302 Cylinder 2 Misfire Detected..................................................................... 1502
Diagnostic Trouble Code (DTC) P0303 Cylinder 3 Misfire Detected..................................................................... 1504
Diagnostic Trouble Code (DTC) P0304 Cylinder 4 Misfire Detected..................................................................... 1506
Diagnostic Trouble Code (DTC) P0305 Cylinder 5 Misfire Detected..................................................................... 1508
Diagnostic Trouble Code (DTC) P0306 Cylinder 6 Misfire Detected..................................................................... 1510
Diagnostic Trouble Code (DTC) P0325 KS Module Circuit............................................................................... 1512
Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit............................................................................... 1514
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit.................................................................... 1517
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency................................................................ 1520
Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performamce.................................................................. 1523
Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low.......................................................................... 1527
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit...................................................................... 1531
Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit...................................................................... 1534
Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit...................................................................... 1537
Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit...................................................................... 1540
Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit...................................................................... 1543
Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit...................................................................... 1546
Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient........................................................................... 1549
Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error.......................................................................... 1552
Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck.................................................................................. 1554
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage................................................................................. 1556
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage................................................................................ 1559
Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1................................................................ 1562
Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2................................................................ 1565
Diagnostic Trouble Code (DTC) P0440 EVAP System..................................................................................... 1568
Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected................................................................. 1573
Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Blocked...................................................................... 1578
Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor Low Voltage........................................................... 1581
Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor High Voltage.......................................................... 1584
Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit-Low Voltage........................................................... 1587
Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit-High Voktage.......................................................... 1590
Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input........................................................................... 1592
Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM................................................................. 1595
Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM................................................................ 1598
Diagnositc Troule Code (DTC) P0562 System Voltage Low............................................................................... 1601
Diagnostic Trouble Code (DTC) P0563 System Voltage High............................................................................. 1603
Diagnostic Trouble Code (DTC) P0601 PCM Memory...................................................................................... 1604
Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage.................................................... 1605
Diagnostic Trouble Code (DTC) P1107 MAP Sensor Circuit Intermittent Low Voltage..................................................... 1607
Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage.................................................... 1609
Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage..................................................... 1612
Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage..................................................... 1614
Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage.................................................... 1616
Diagnostic Trouble Code (DTC) P1121 TP Sensor Circuit Intermittent High Voltage..................................................... 1619
Diagnostic Trouble Code (DTC) P1122 TP Sensor Circuit Intermittent Low Voltage...................................................... 1621
Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1..................................................... 1623
Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1...................................................... 1627
Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1..................................................... 1631
Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1.............................................. 1635
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean Dueing Acceleration............................................................ 1639
Diagnostic Trouble Code (DTC) P1380 ABS Rough Road ABS System Fault................................................................. 1642
Diagnostic Trouble Code (DTC) P1381 ABS Rough Road Class 2 Serial Link.............................................................. 1643
Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed................................................................................ 1644
Diagnostic Trouble Code (DTC) P1381 ABS Rough Road Class 2 Serial Link Error........................................................ 1643
Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed................................................................................ 1644
Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge............................................................... 1647
Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM.............................................................................. 1650
Diagnostic Trouble Code (DTC) P1509 IAC System High RPM............................................................................. 1653
Diagnostic Trouble Code (DTC) P1618 Serial Peripheral Interface (SPI) PCM Interprocessor Communication Error........................ 1656
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset............................................................................ 1657
Diagnostic Trouble Code (DTC) P1640 Output Driver Module (ODM) "A" Fault............................................................ 1658
Diagnostic Trouble Code (DTC) P1650 Quad Driver Module "A" Fault.................................................................... 1660
Symptom Diagnosis................................................................................................................... 1663
Default Matrix Table................................................................................................................ 1691
On-Vehicle Service Camshaft Position (CMP) Sensor................................................................................... 1694
Crankshaft Position (CKP) Sensor.................................................................................................... 1695
Engine Coolant Temperature (ECT) Sensor............................................................................................. 1695
Heated Oxygen Sensor (HO2S)......................................................................................................... 1696
Intake Air Temperature (IAT) Sensor................................................................................................. 1698
Knock Sensor (KS)................................................................................................................... 1699
Mass Air Flow (MAF) Sensor.......................................................................................................... 1700
Manifold Absolute Pressure (MAP) Sensor............................................................................................. 1701
Malfunction Indicator Lamp (MIL).................................................................................................... 1701
Powertrain Control Module (PCM)..................................................................................................... 1702
EEPROM.............................................................................................................................. 1703
Throttle Position (TP) Sensor....................................................................................................... 1704
Vehicle Speed Sensor (VSS).......................................................................................................... 1704
Air Cleaner/Air Filter.............................................................................................................. 1706
Idle Air Control (IAC) Valve........................................................................................................ 1707
Common Chamber...................................................................................................................... 1708
Accelerator Cable Assembly.......................................................................................................... 1708
Accelerator Pedal Replacement....................................................................................................... 1711
Fuel Fillter Cap.................................................................................................................... 1713
Fuel Filter......................................................................................................................... 1713
Fuel Gauge Unit..................................................................................................................... 1716
Fuel Injectors...................................................................................................................... 1716
Fuel Pressure Regulator............................................................................................................. 1717
Fuel Metering System................................................................................................................ 1719
Fuel Pump Assembly.................................................................................................................. 1719
Fuel Pump Relay..................................................................................................................... 1720
Fuel Rail Assembly.................................................................................................................. 1720
Fuel Tank........................................................................................................................... 1721
Throttle Body (TB).................................................................................................................. 1721
Electronic Ignition System.......................................................................................................... 1723
Catalytic Converter................................................................................................................. 1724
Air Conditioning Relay.............................................................................................................. 1724
EVAP Canister Hoses................................................................................................................. 1724
EVAP Canister....................................................................................................................... 1725
EVAP Canister Vent Solenoid......................................................................................................... 1726
Fuel Tank Pressure Sensor........................................................................................................... 1727
EVAP Canister Purge Solenoid........................................................................................................ 1728
Fuel Tank Vent Valve................................................................................................................ 1729
Linear Exhaust Gas Recircula-tion (EGR) Valve....................................................................................... 1729
Positive Crankcase Ventilation (PCV) Valve.......................................................................................... 1730
Wiring and Connectors............................................................................................................... 1730
PCM Connectors and Terminals........................................................................................................ 1731
Wire Harness Repair: Twisted Shielded Cable......................................................................................... 1731
Twisted Leads....................................................................................................................... 1732
Weather-Pack Connector.............................................................................................................. 1733
Com-Pack III........................................................................................................................ 1734
Metri-Pack.......................................................................................................................... 1734
General Description (PCM and Sensors)............................................................................................... 1736
58X Reference PCM Input......................................................................................................... 1736
A/C Request Signal.............................................................................................................. 1736
Crankshaft Position (CKP) Sensor................................................................................................ 1736
Camshaft Position (CMP) Sensor and Signal....................................................................................... 1736
Engine Coolant Temperature (ECT) Sensor......................................................................................... 1736
Electrically Erasable Programmable Read Only Memory (EEPROM).................................................................... 1737
Fuel Control Heated Oxygen Sensors.............................................................................................. 1737
Catalyst Monitor Heated Oxygen Sensors.......................................................................................... 1737
Intake Air Temperature (IAT) Sensor............................................................................................. 1738
Knock Sensor.................................................................................................................... 1738
Linear Exhaust Gas Recirculation (EGR) Control.................................................................................. 1739
Mass Air Flow (MAF) Sensor...................................................................................................... 1739
Manifold Absolute Pressure (MAP) Sensor......................................................................................... 1739
Powertrain Control Module (PCM)................................................................................................. 1740
PCM Function.................................................................................................................... 1740
PCM Components.................................................................................................................. 1740
PCM Voltage Description......................................................................................................... 1740
PCM Input/Outputs............................................................................................................... 1740
PCM Service Precautions......................................................................................................... 1741
Reprogramming The PCM........................................................................................................... 1741
Throttle Position (TP) Sensor................................................................................................... 1741
Transmission Fluid Temperature (TFT) Sensor..................................................................................... 1741
Transmission Range Switch....................................................................................................... 1741
Vehicle Speed Sensor (VSS)...................................................................................................... 1742
Use of Circuit Testing Tools.................................................................................................... 1742
Aftermarket Electrical and Vacuum Equipment..................................................................................... 1742
Electrostatic Discharge Damage.................................................................................................. 1742
Upshift Lamp.................................................................................................................... 1743
General Description (Air Induction)................................................................................................. 1743
Air Induction System............................................................................................................ 1743
General Description (Fuel Metering)................................................................................................. 1743
Acceleration Mode............................................................................................................... 1743
Accelerator Controls............................................................................................................ 1743
Battery Voltage Correction Mode................................................................................................. 1743
CMP Signal...................................................................................................................... 1743
Clear Flood Mode................................................................................................................ 1743
Deceleration Mode............................................................................................................... 1743
Engine Speed/Vehicle Speed/Fuel Disable Mode.................................................................................... 1743
Fuel Cutoff Mode................................................................................................................ 1743
Fuel Injector................................................................................................................... 1743
Fuel Metering System Components................................................................................................. 1744
Fuel Metering System Purpose.................................................................................................... 1744
Fuel Pressure Regulator......................................................................................................... 1744
Fuel Pump Electrical Circuit.................................................................................................... 1744
Fuel Rail....................................................................................................................... 1744
Idle Air Control (IAC) Valve.................................................................................................... 1745
Run Mode........................................................................................................................ 1745
Starting Mode................................................................................................................... 1745
Throttle Body Unit.............................................................................................................. 1746
General Description (Electronic Ignition System).................................................................................... 1746
Camshaft Position (CMP) Sensor.................................................................................................. 1746
Crankshaft Position (CKP) Sensor................................................................................................ 1746
Electronic Ignition............................................................................................................. 1746
Ignition Coils.................................................................................................................. 1747
Ignition Control................................................................................................................ 1747
Ignition Control PCM Output..................................................................................................... 1748
Knock Sensor (KS) PCM Input..................................................................................................... 1748
Powertrain Control Module (PCM)................................................................................................. 1748
Spark Plug...................................................................................................................... 1748
A/C Clutch Diagnosis................................................................................................................ 1750
A/C Clutch Circuit Operation.................................................................................................... 1750
A/C Clutch Circuit Purpose...................................................................................................... 1750
A/C Request Signal.............................................................................................................. 1750
General Description (Evaporative (EVAP) Emission System)............................................................................ 1751
EVAP Emission Control System Purpose............................................................................................ 1751
EVAP Emission Control System Operation.......................................................................................... 1751
Enhanced Evaporative Emission Control System.................................................................................... 1751
General Description (Exhaust Gas Recirculation (EGR) System)........................................................................ 1754
EGR Purpose..................................................................................................................... 1754
Linear EGR Valve................................................................................................................ 1755
Linear EGR Control.............................................................................................................. 1755
Linear EGR Valve Operation and Results of Incorrect Operation................................................................... 1755
EGR Pintle Position Sensor...................................................................................................... 1755
General Description (Positive Crankcase Ventilation (PCV) System)................................................................... 1755
Crankcase Ventilation System Purpose............................................................................................ 1755
Crankcase Ventilation System Operation.......................................................................................... 1756
Special Tools....................................................................................................................... 1757
6F ENGINE EXHAUST (6VD1 3.2L)......................................................................................................... 1759
Service Precaution.................................................................................................................. 1759
General Description................................................................................................................. 1760
Three Way Catalytic Converter RH and Forked Exhaust Pipe............................................................................ 1761
Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts................................................... 1761
Removal......................................................................................................................... 1761
Installation.................................................................................................................... 1761
Three Way Catalytic Converter LH and Forked Exhaust Pipe............................................................................ 1762
Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated Parts................................................... 1762
Removal......................................................................................................................... 1762
Installation.................................................................................................................... 1762
Forked Exhaust Pipe................................................................................................................. 1763
Forked Exhaust Pipe and Associated Parts........................................................................................ 1763
Removal......................................................................................................................... 1763
Installation.................................................................................................................... 1763
Exhaust Silencer.................................................................................................................... 1764
Exhaust Silencer and Associated Parts........................................................................................... 1764
Removal......................................................................................................................... 1764
Installation.................................................................................................................... 1764
Rear Exhaust pipe................................................................................................................... 1765
Rear Exhaust pipe and Associated Parts.......................................................................................... 1765
Removal......................................................................................................................... 1765
Installation.................................................................................................................... 1765
Main Data and Specifications........................................................................................................ 1766
6G ENGINE LUBRICATION (6VD1 3.2L)..................................................................................................... 1767
Service Precaution.................................................................................................................. 1767
General Description................................................................................................................. 1768
Oil Pump............................................................................................................................ 1769
Oil Pump and Associated Parts................................................................................................... 1769
Disassembly..................................................................................................................... 1770
Inspection and Repair........................................................................................................... 1770
Reassembly...................................................................................................................... 1771
Oil Pan and Crankcase............................................................................................................... 1773
Removal......................................................................................................................... 1773
Installation.................................................................................................................... 1773
Oil Pump............................................................................................................................ 1775
Removal......................................................................................................................... 1775
Installation.................................................................................................................... 1775
Oil Pump Oil Seal................................................................................................................... 1777
Removal......................................................................................................................... 1777
Installation.................................................................................................................... 1777
Oil Filter.......................................................................................................................... 1778
Removal......................................................................................................................... 1778
Installation.................................................................................................................... 1778
Main Data and Specification......................................................................................................... 1779
6H ENGINE SPEED CONTROL SYSTEM (6VD1 3.2L)............................................................................................ 1780
Service Precaution.................................................................................................................. 1780
Accelerator Pedal Control Cable..................................................................................................... 1781
Removal......................................................................................................................... 1781
Inspection...................................................................................................................... 1781
Installation.................................................................................................................... 1781
Accelerator Pedal................................................................................................................... 1782
Accelerator Pedal and Associated Parts.......................................................................................... 1782
Removal......................................................................................................................... 1782
Installation.................................................................................................................... 1782
6J INDUCTION (6VD1 3.2L).............................................................................................................. 1783
Service Precaution.................................................................................................................. 1783
Air Cleaner Element................................................................................................................. 1784
Removal......................................................................................................................... 1784
Inspection...................................................................................................................... 1784
Installation.................................................................................................................... 1784
Sec.7 TRANSMISSION............................................................................................................................ 1785
7A AUTOMATIC TRANSMISSION (4L30-E)........................................................................................................ 1785
Service Precaution...................................................................................................................... 1786
Construction............................................................................................................................ 1787
Range Reference Chart................................................................................................................... 1788
Normal Operation of 1999 4L30-E Transmission............................................................................................ 1789
Diagnosis............................................................................................................................... 1789
General Diagnosis Procedure............................................................................................................. 1792
Preliminary Inspection Chart............................................................................................................ 1793
Checking Transmission Fluid Level and Condition......................................................................................... 1794
Test Driving............................................................................................................................ 1795
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................ 1796
Mechanical / Hydraulic Diagnosis Symptoms Index......................................................................................... 1797
Stall Test.............................................................................................................................. 1806
Line Pressure Test...................................................................................................................... 1807
Shift Speed Chart....................................................................................................................... 1808
Lockup Speed Chart...................................................................................................................... 1809
Changing Transmission Fluid............................................................................................................. 1810
Selector Lever.......................................................................................................................... 1810
Inspection.......................................................................................................................... 1810
Removal............................................................................................................................. 1810
Installation........................................................................................................................ 1811
Select Cable............................................................................................................................ 1812
Removal............................................................................................................................. 1812
Installation........................................................................................................................ 1814
Shift Lock Cable........................................................................................................................ 1816
Removal............................................................................................................................. 1816
Installation........................................................................................................................ 1817
Mode Switch............................................................................................................................. 1818
Removal............................................................................................................................. 1818
Installation........................................................................................................................ 1818
Transmission............................................................................................................................ 1820
Transmission and Associated Parts................................................................................................... 1820
Removal............................................................................................................................. 1821
Installation........................................................................................................................ 1823
Solenoid (Main Case Valve Body)......................................................................................................... 1828
Removal............................................................................................................................. 1828
Installation........................................................................................................................ 1828
Solenoid (Adapter Case Valve Body)...................................................................................................... 1829
Removal............................................................................................................................. 1829
Installation........................................................................................................................ 1829
Valve Body Assembly (Main Case)......................................................................................................... 1830
Removal............................................................................................................................. 1830
Installation........................................................................................................................ 1830
Valve Body Assembly (Adapter Case)...................................................................................................... 1831
Removal............................................................................................................................. 1831
Installation........................................................................................................................ 1831
Powertrain Control Module (PCM)......................................................................................................... 1832
Removal............................................................................................................................. 1832
Installation........................................................................................................................ 1832
Speed Sensor (Extension Housing)........................................................................................................ 1833
Removal............................................................................................................................. 1833
Installation........................................................................................................................ 1833
Transmission Oil Temperature Sensor (Adapter Case)...................................................................................... 1833
Removal............................................................................................................................. 1833
Installation........................................................................................................................ 1833
Front Oil Seal (Converter Housing)...................................................................................................... 1834
Removal............................................................................................................................. 1834
Installation........................................................................................................................ 1834
Rear Oil Seal (Extension Housing)....................................................................................................... 1834
Removal............................................................................................................................. 1834
Installation........................................................................................................................ 1834
Transmission (4L30-E)................................................................................................................... 1835
Disassembly......................................................................................................................... 1835
Reassembly.......................................................................................................................... 1839
Converter Housing and Oil Pump Assembly................................................................................................. 1849
Disassembled View................................................................................................................... 1849
Disassembly......................................................................................................................... 1849
Inspection and Repair............................................................................................................... 1849
Reassembly.......................................................................................................................... 1849
Oil Pump................................................................................................................................ 1850
Disassembled View................................................................................................................... 1850
Disassembly......................................................................................................................... 1850
Inspection and Repair............................................................................................................... 1850
Reassembly.......................................................................................................................... 1850
Main Case Valve Body.................................................................................................................... 1851
Disassembled View................................................................................................................... 1851
Disassembly......................................................................................................................... 1852
Inspection and Repair............................................................................................................... 1852
Reassembly.......................................................................................................................... 1852
Adapter Case Valve Body................................................................................................................. 1853
Disassembled View................................................................................................................... 1853
Disassembly......................................................................................................................... 1853
Inspection and Repair............................................................................................................... 1853
Reassembly.......................................................................................................................... 1853
Third Clutch and Sprag Unit............................................................................................................. 1854
Disassembled View................................................................................................................... 1854
Disassembly......................................................................................................................... 1854
Inspection and Repair............................................................................................................... 1855
Reassembly.......................................................................................................................... 1855
Third Clutch............................................................................................................................ 1855
Disassembled View................................................................................................................... 1855
Disassemble......................................................................................................................... 1856
Inspection and Repair............................................................................................................... 1856
Reassembly.......................................................................................................................... 1856
Sprag Unit.............................................................................................................................. 1857
Disassembled View................................................................................................................... 1857
Disassembly......................................................................................................................... 1857
Inspection and Repair............................................................................................................... 1857
Reassembly.......................................................................................................................... 1857
Second Clutch........................................................................................................................... 1858
Disassembled View................................................................................................................... 1858
Disassembly......................................................................................................................... 1858
Inspection and Repair............................................................................................................... 1859
Reassembly.......................................................................................................................... 1859
3-4 Accumulator Piston.................................................................................................................. 1860
Disassembled View................................................................................................................... 1860
Disassembly......................................................................................................................... 1860
Inspection and Repair............................................................................................................... 1860
Reassembly.......................................................................................................................... 1861
Reverse Clutch Piston and Center Support................................................................................................ 1862
Disassembled View................................................................................................................... 1862
Disassembly......................................................................................................................... 1863
Inspection and Repair............................................................................................................... 1863
Reassembly.......................................................................................................................... 1863
Overrun Clutch and Turbine Shaft........................................................................................................ 1864
Disassembled View................................................................................................................... 1864
Disassembly......................................................................................................................... 1865
Inspection and Repair............................................................................................................... 1865
Reassembly.......................................................................................................................... 1865
Main Data and Specification............................................................................................................. 1867
Special Tools........................................................................................................................... 1871
4L30-E Parts List....................................................................................................................... 1874
7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)................................................................................................... 1882
Service Precaution...................................................................................................................... 1883
General Description..................................................................................................................... 1883
Electronic Control Diagram.......................................................................................................... 1884
Powertrain Control Module (PCM)..................................................................................................... 1885
Control System Diagram.............................................................................................................. 1886
Shift Control....................................................................................................................... 1887
Band Apply Control.................................................................................................................. 1887
Torque Converter Clutch Control..................................................................................................... 1887
Line Pressure Control............................................................................................................... 1887
On-Board Diagnostic System.......................................................................................................... 1887
Fail-Safe Mechanism................................................................................................................. 1887
Torque Management Control........................................................................................................... 1887
ATF Warning Control................................................................................................................. 1887
Shift Mode Control.................................................................................................................. 1888
Gear Shift Control.................................................................................................................. 1889
Winter Drive Mode................................................................................................................... 1890
Functions of Input / Output Components.............................................................................................. 1891
Diagnosis............................................................................................................................... 1892
Electronic Diagnosis................................................................................................................ 1892
How To Diagnose The Problem......................................................................................................... 1892
Check Trans Indicator............................................................................................................... 1892
Diagnostic Check.................................................................................................................... 1892
"Check Trans" Check................................................................................................................. 1893
Tech-2 OBD II Connection............................................................................................................ 1894
F0: Transmission Data............................................................................................................... 1898
F1: PC Solenoid Data................................................................................................................ 1899
OBD II Diagnostic Management System................................................................................................. 1900
16-Terminal Data Link Connector (DLC)............................................................................................... 1901
Malfunction Indicator Lamp (MIL).................................................................................................... 1902
Types Of Diagnostic Trouble Codes (DTCs)............................................................................................ 1902
Clear DTC........................................................................................................................... 1902
DTC Check........................................................................................................................... 1903
PCM Precaution...................................................................................................................... 1903
Information On PCM.................................................................................................................. 1903
Intermittent Conditions............................................................................................................. 1904
Transmission and PCM Identification................................................................................................. 1904
Isuzu Rodeo......................................................................................................................... 1905
Diagnostic Trouble Code (DTC) Identification........................................................................................ 1906
DTC P0218 Transmission Fluid Over Temperature........................................................................................... 1907
DTC P0560 System Voltage Malfunction.................................................................................................... 1909
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position...................................................................... 1912
DTC P0706 Transmission Range Switch (Mode Switch) Performance........................................................................... 1915
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Circuit Range/Performance......................................................... 1918
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input................................................................. 1921
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................ 1924
DTC P0719 TCC Brake Switch Circuit High (Stuck On)...................................................................................... 1927
DTC P0722 Transmission Output Speed Sensor (OSS) Low Input.............................................................................. 1930
DTC P0723 Transmission Output Speed Sensor (OSS) Intermittent........................................................................... 1933
DTC P0724 TCC Brake Switch Circuit Low (Stuck Off)...................................................................................... 1936
DTC P0730 Transmission Incorrect Gear Ratio............................................................................................. 1938
DTC P0742 Torque Converter Clutch (TCC) Circuit Stuck On................................................................................ 1941
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical.............................................................. 1943
DTC P0751 Shift Solenoid A Performance Without Input Speed.............................................................................. 1945
DTC P0753 Shift Solenoid A Electrical................................................................................................... 1947
DTC P0756 Shift Solenoid B Performance Without Input Speed.............................................................................. 1950
DTC P0758 Shift Solenoid B Electrical................................................................................................... 1952
DTC P1790 ROM Transmission Side Bad Check Sum........................................................................................... 1956
DTC P1792 EEPROM Transmission Side Bad Check Sum........................................................................................ 1957
DTC P1835 Kickdown Switch Always On..................................................................................................... 1958
DTC P1850 Brake Band Apply Solenoid Malfunction......................................................................................... 1960
DTC P1860 TCC Solenoid Electrical....................................................................................................... 1964
DTC P1870 Transmission Component Slipping............................................................................................... 1967
7B MANUAL TRANSMISSION MUA 5C (4X2, 4X4) AND TREMEC T5R(4X2).............................................................................. 1969
Service Precaution...................................................................................................................... 1970
General Description..................................................................................................................... 1970
Diagnosis (MUA)......................................................................................................................... 1973
Diagnosis (TREMEC T5R).................................................................................................................. 1974
Rear Oil Seal (4X2)..................................................................................................................... 1975
Disassembled View................................................................................................................... 1975
Removal............................................................................................................................. 1975
Installation........................................................................................................................ 1975
Transmission (MUA)...................................................................................................................... 1976
Disassembled View................................................................................................................... 1976
Removal............................................................................................................................. 1977
Installation........................................................................................................................ 1981
Transmission (TREMEC T5R)............................................................................................................... 1986
Disassembled View................................................................................................................... 1986
Removal............................................................................................................................. 1987
Installation........................................................................................................................ 1989
Transmission Case....................................................................................................................... 1993
Major Component (MUA, 4X2).......................................................................................................... 1993
Disassembly......................................................................................................................... 1994
Reassembly.......................................................................................................................... 1995
Transmission Case and Transfer Case..................................................................................................... 1998
Major Component (MUA, 4X4).......................................................................................................... 1998
Disassembly......................................................................................................................... 1999
Reassembly.......................................................................................................................... 2002
Intermediate Plate with Gear Assembly, Detent, Shift Arm, and Interlock Pin (MUA)....................................................... 2008
Disassembled View................................................................................................................... 2008
Disassembly......................................................................................................................... 2009
Inspection and Repair............................................................................................................... 2010
Reassembly.......................................................................................................................... 2011
Reverse Gear and 5th Gear (MUA)......................................................................................................... 2012
Disassembled View................................................................................................................... 2012
Disassembly......................................................................................................................... 2013
Inspection and Repair............................................................................................................... 2015
Reassembly.......................................................................................................................... 2015
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft (MUA)........................................................................... 2021
Disassmebled View................................................................................................................... 2021
Disassembly......................................................................................................................... 2022
Reassembly.......................................................................................................................... 2026
Transmission Case (TREMEC T5R).......................................................................................................... 2032
Disassembled View................................................................................................................... 2032
Disassembly......................................................................................................................... 2033
Inspection and Repair............................................................................................................... 2039
Reassembly.......................................................................................................................... 2044
Mainshaft (TREMEC T5R).................................................................................................................. 2050
Disassembled View................................................................................................................... 2050
Disassembly......................................................................................................................... 2050
Reassembly.......................................................................................................................... 2053
Input Shaft (TREMEC T5R)................................................................................................................ 2055
Disassembled View................................................................................................................... 2055
Disassembly......................................................................................................................... 2055
Reassembly.......................................................................................................................... 2056
Input Bearing Retainer (TREMEC T5R)..................................................................................................... 2057
Disassembled View................................................................................................................... 2057
Disassembly......................................................................................................................... 2057
Reassembly.......................................................................................................................... 2057
Counter Shaft (TREMEC T5R).............................................................................................................. 2058
Disassembled View................................................................................................................... 2058
Disassembly......................................................................................................................... 2058
Reassembly.......................................................................................................................... 2059
Extension Housing (TREMEC T5R).......................................................................................................... 2060
Disassembled View................................................................................................................... 2060
Disassembly......................................................................................................................... 2060
Reassembly.......................................................................................................................... 2061
Shift Cover (TREMEC T5R)................................................................................................................ 2062
Disassembled View................................................................................................................... 2062
Disassembly......................................................................................................................... 2062
Reassembly.......................................................................................................................... 2063
Pre-Installation Checks (TREMEC T5R)................................................................................................ 2066
Main Data and Specifications............................................................................................................ 2068
Special Tools (MUA)..................................................................................................................... 2074
Special Tools (TREMEC T5R).............................................................................................................. 2076
7C CLUTCH................................................................................................................................. 2078
Service Precaution...................................................................................................................... 2078
General Description..................................................................................................................... 2079
Diagnosis............................................................................................................................... 2085
Clutch Assembly (X22SE, TREMEC T5R / MUA)............................................................................................... 2086
Clutch Assembly (X22SE, TREMEC T5R) and Associated Parts............................................................................ 2086
Clutch Assembly (X22SE, MUA) and Associated Parts................................................................................... 2087
Removal............................................................................................................................. 2087
Inspection and Repair............................................................................................................... 2088
Installation........................................................................................................................ 2092
Clutch Assembly (6VD1, MUA)............................................................................................................. 2095
Clutch Assembly (6VD1, MUA) and Associated Parts.................................................................................... 2095
Removal............................................................................................................................. 2095
Inspection and Repair............................................................................................................... 2097
Installation........................................................................................................................ 2101
Clutch Control.......................................................................................................................... 2103
Parts Location View................................................................................................................. 2103
Removal............................................................................................................................. 2104
Inspection and Repair............................................................................................................... 2104
Installation........................................................................................................................ 2105
Master Cylinder......................................................................................................................... 2107
Slave Cylinder...................................................................................................................... 2108
Disassembled View................................................................................................................... 2108
Disassembly......................................................................................................................... 2108
Inspection and Repair............................................................................................................... 2108
Reassembly.......................................................................................................................... 2109
Main Data and Specifications............................................................................................................ 2110
Special Tools........................................................................................................................... 2113
Sec.8 BODY AND ACCESSORIES.................................................................................................................... 2114
8A LIGHTING SYSTEM........................................................................................................................ 2114
Service Precaution...................................................................................................................... 2114
Headlight Bulb.......................................................................................................................... 2115
Headlight Assembly...................................................................................................................... 2115
Headlight Adjustment................................................................................................................ 2116
Fog Light Bulb.......................................................................................................................... 2116
Fog Light Assembly...................................................................................................................... 2117
Fog Light Adjustment................................................................................................................ 2117
Side Marker Light Bulb.................................................................................................................. 2117
Front Combination Light Assembly........................................................................................................ 2118
Taillight Bulb.......................................................................................................................... 2118
License Plate Light Bulb (Bumper Type).................................................................................................. 2119
License Plate Light Bulb (Tailgate Type)................................................................................................ 2119
Stoplight Bulb.......................................................................................................................... 2120
High Mounted Stoplight Assembly......................................................................................................... 2120
High Mounted Stoplight Bulb............................................................................................................. 2121
Backup Light Bulb....................................................................................................................... 2121
Front Turn Signal Light Bulb............................................................................................................ 2122
Rear Turn Signal Light Bulb............................................................................................................. 2122
Dome Light Bulb......................................................................................................................... 2123
Courtesy Light Bulb..................................................................................................................... 2123
Spotlight Bulb.......................................................................................................................... 2124
Luggage Room Light Bulb................................................................................................................. 2124
HVAC Bezel Illumination Light Bulb...................................................................................................... 2125
Shift Lever Illumination Light Bulb (A/T)............................................................................................... 2125
Vanity Mirror Illumination Light Bulb................................................................................................... 2126
Starter Switch.......................................................................................................................... 2126
Lighting Switch (Combination Switch).................................................................................................... 2127
DimmerｷPassing Switch (Combination Switch).............................................................................................. 2127
Door Switch............................................................................................................................. 2128
Rear Defogger Switch.................................................................................................................... 2128
Key Remind Switch (Starter Switch)...................................................................................................... 2129
Hazard Warning Light Switch............................................................................................................. 2129
Stoplight Switch........................................................................................................................ 2129
Backup Light Switch (M/T)............................................................................................................... 2130
Turn Signal Light Switch (Combination Switch)........................................................................................... 2130
Illumination Controller................................................................................................................. 2130
Light and Bulb Specifications........................................................................................................... 2131
8B WIPER / WASHER SYSTEM.................................................................................................................. 2133
Service Precaution...................................................................................................................... 2133
Windshield Wiper/Washer System.......................................................................................................... 2134
General Description................................................................................................................. 2134
Windshield Wiper And Washer Switch...................................................................................................... 2134
Removal and Installation............................................................................................................ 2134
Windshield Wiper Motor.................................................................................................................. 2134
Removal............................................................................................................................. 2134
Installation........................................................................................................................ 2134
Windshield Washer Motor................................................................................................................. 2135
Removal............................................................................................................................. 2135
Installation........................................................................................................................ 2135
Windshield Washer Spray Pattern......................................................................................................... 2136
Windshield Wiper Linkage............................................................................................................ 2137
Windshield Wiper Linkage and Associated Parts....................................................................................... 2137
Removal............................................................................................................................. 2137
Installation........................................................................................................................ 2137
Windshield Wiper Arm/Blade.............................................................................................................. 2138
Removal............................................................................................................................. 2138
Installation........................................................................................................................ 2138
Windshield Wiper Blade Rubber........................................................................................................... 2139
Removal............................................................................................................................. 2139
Installation........................................................................................................................ 2139
Rear Wiper/Washer System................................................................................................................ 2140
General Description................................................................................................................. 2140
Rear Wiper and Washer Switch............................................................................................................ 2140
Removal............................................................................................................................. 2140
Installation........................................................................................................................ 2140
Rear Wiper Motor........................................................................................................................ 2141
Removal............................................................................................................................. 2141
Installation........................................................................................................................ 2141
Rear Washer Motor....................................................................................................................... 2142
Removal............................................................................................................................. 2142
Installation........................................................................................................................ 2142
Alarm and Relay Control Unit............................................................................................................ 2142
Removal............................................................................................................................. 2142
Installation........................................................................................................................ 2142
Rear Wiper Arm/Blade.................................................................................................................... 2143
Removal............................................................................................................................. 2143
Installation........................................................................................................................ 2143
Rear Washer Nozzle...................................................................................................................... 2143
Removal............................................................................................................................. 2143
Installation........................................................................................................................ 2143
Rear Washer Spray Pattern........................................................................................................... 2143
Rear Wiper Blade Rubber................................................................................................................. 2144
Removal............................................................................................................................. 2144
Installation........................................................................................................................ 2144
Main Data and Specifications............................................................................................................ 2145
8C ENTERTAINMENT.......................................................................................................................... 2146
Service Precaution...................................................................................................................... 2146
Cigarette Lighter....................................................................................................................... 2147
General Description................................................................................................................. 2147
Removal............................................................................................................................. 2147
Installation........................................................................................................................ 2147
Digital Clock........................................................................................................................... 2147
Removal............................................................................................................................. 2147
Installation........................................................................................................................ 2148
Rod Type Antenna........................................................................................................................ 2148
Removal............................................................................................................................. 2148
Installation........................................................................................................................ 2148
Accessory Socket........................................................................................................................ 2149
Front Accessory Socket.............................................................................................................. 2149
Rear Accessory Socket............................................................................................................... 2149
Radio................................................................................................................................... 2150
Removal............................................................................................................................. 2150
Installation........................................................................................................................ 2150
Speaker................................................................................................................................. 2151
Front Speaker....................................................................................................................... 2151
Tweeter Assembly.................................................................................................................... 2151
Rear Speaker........................................................................................................................ 2151
Horn.................................................................................................................................... 2152
Removal............................................................................................................................. 2152
Installation........................................................................................................................ 2152
8D WIRING SYSTEM.......................................................................................................................... 2153
Service Precaution...................................................................................................................... 2154
General Description..................................................................................................................... 2155
Main Data and Specifications............................................................................................................ 2177
Start and Charging...................................................................................................................... 2197
General Description................................................................................................................. 2197
Circuit Diagram..................................................................................................................... 2198
Parts Location...................................................................................................................... 2201
Powertrain Control Module (PCM)......................................................................................................... 2202
General Description................................................................................................................. 2202
Circuit Diagram..................................................................................................................... 2203
Parts Location...................................................................................................................... 2216
Circuit Diagram..................................................................................................................... 2219
Parts Location...................................................................................................................... 2229
Headlight and Fog Light................................................................................................................. 2231
General Description................................................................................................................. 2231
Circuit Diagram..................................................................................................................... 2232
Parts Location...................................................................................................................... 2234
Diagnosis........................................................................................................................... 2235
Front Side Marker Light, Parking Light, Tail Light and License Plate Light.............................................................. 2238
General Description................................................................................................................. 2238
Circuit Diagram..................................................................................................................... 2239
Parts Location...................................................................................................................... 2241
Diagnosis........................................................................................................................... 2242
Interior Illumination Light............................................................................................................. 2245
General Description................................................................................................................. 2245
Circuit Diagram..................................................................................................................... 2246
Parts Location...................................................................................................................... 2250
Turn Signal Light, Hazard Warning Light................................................................................................. 2251
General Description................................................................................................................. 2251
Circuit Diagram..................................................................................................................... 2252
Parts Location...................................................................................................................... 2255
Diagnosis........................................................................................................................... 2256
Stoplight............................................................................................................................... 2258
General Description................................................................................................................. 2258
Circuit Diagram..................................................................................................................... 2259
Parts Location...................................................................................................................... 2260
Diagnosis........................................................................................................................... 2261
Backup Light............................................................................................................................ 2263
General Description................................................................................................................. 2263
Circuit Diagram..................................................................................................................... 2264
Parts Location...................................................................................................................... 2265
Diagnosis........................................................................................................................... 2266
Horn.................................................................................................................................... 2267
General Description................................................................................................................. 2267
Circuit Diagram..................................................................................................................... 2268
Parts Location...................................................................................................................... 2269
Diagnosis........................................................................................................................... 2270
Dome Light, Luggage Room Light, Courtesy Light, Map Light, Seat Belt Switch and Warning Buzzer.......................................... 2271
General Description................................................................................................................. 2271
Circuit Diagram..................................................................................................................... 2272
Parts Location...................................................................................................................... 2277
Power Door Lock......................................................................................................................... 2278
General Description................................................................................................................. 2278
Circuit Diagram..................................................................................................................... 2279
Parts Location...................................................................................................................... 2283
Diagnosis........................................................................................................................... 2284
Power Window............................................................................................................................ 2286
General Description................................................................................................................. 2286
Circuit Diagram..................................................................................................................... 2287
Parts Location...................................................................................................................... 2288
Diagnosis........................................................................................................................... 2289
Cruise Control.......................................................................................................................... 2293
General Description................................................................................................................. 2293
Circuit Diagram..................................................................................................................... 2294
Parts Location...................................................................................................................... 2296
Diagnosis........................................................................................................................... 2297
Diagnosis........................................................................................................................... 2299
Anti-Lock Brake System (ABS)............................................................................................................ 2301
General Description................................................................................................................. 2301
Circuit Diagram..................................................................................................................... 2302
Parts Location...................................................................................................................... 2305
A/T Shift Lock.......................................................................................................................... 2306
General Description................................................................................................................. 2306
Circuit Diagram..................................................................................................................... 2307
Parts Location...................................................................................................................... 2308
Windshield Wiper and Washer............................................................................................................. 2309
General Description................................................................................................................. 2309
Circuit Diagram..................................................................................................................... 2310
Parts Location...................................................................................................................... 2312
Diagnosis........................................................................................................................... 2313
Rear Wiper/Washer....................................................................................................................... 2319
General Description................................................................................................................. 2319
Circuit Diagram..................................................................................................................... 2320
Parts Location...................................................................................................................... 2323
Diagnosis........................................................................................................................... 2324
Rear Defogger/Mirror Defogger........................................................................................................... 2329
General Description................................................................................................................. 2329
Circuit Diagram..................................................................................................................... 2330
Parts Location...................................................................................................................... 2332
Diagnosis........................................................................................................................... 2333
Parts Location...................................................................................................................... 2332
Diagnosis........................................................................................................................... 2333
Audio................................................................................................................................... 2336
General Description................................................................................................................. 2336
Circuit Diagram..................................................................................................................... 2337
Parts Location...................................................................................................................... 2338
Cigarette Lighter, Digital Clock and Accessory Socket................................................................................... 2339
General Description................................................................................................................. 2339
Circuit Diagram..................................................................................................................... 2340
Parts Location...................................................................................................................... 2341
Diagnosis........................................................................................................................... 2342
Power Door Mirror....................................................................................................................... 2343
General Description................................................................................................................. 2343
Circuit Diagram..................................................................................................................... 2344
Parts Location...................................................................................................................... 2346
Diagnosis........................................................................................................................... 2347
Keyless Entry and Anti-Theft System..................................................................................................... 2348
General Description................................................................................................................. 2348
Circuit Diagram..................................................................................................................... 2349
Parts Location...................................................................................................................... 2354
Diagnosis........................................................................................................................... 2355
Meter and Warning/Indicator Light....................................................................................................... 2365
General Description................................................................................................................. 2365
Circuit Diagram..................................................................................................................... 2366
Parts Location...................................................................................................................... 2373
Diagnosis........................................................................................................................... 2374
A/T Shift Indicator..................................................................................................................... 2380
General Description................................................................................................................. 2380
Circuit Diagram..................................................................................................................... 2381
Parts Location...................................................................................................................... 2383
Heater and Air Conditioning............................................................................................................. 2384
General Description................................................................................................................. 2384
Circuit Diagram..................................................................................................................... 2385
Parts Location...................................................................................................................... 2388
Sun Roof................................................................................................................................ 2389
General Description................................................................................................................. 2389
Circuit Diagram..................................................................................................................... 2390
Parts Location...................................................................................................................... 2391
Diagnosis........................................................................................................................... 2392
Supplemental Restraint System (SRS) -Air Bag............................................................................................ 2393
General Description................................................................................................................. 2393
Circuit Diagram..................................................................................................................... 2394
Parts Location...................................................................................................................... 2395
Shift on the Fly System................................................................................................................. 2396
General Description................................................................................................................. 2396
Circuit Diagram..................................................................................................................... 2397
Parts Location...................................................................................................................... 2399
Harness Connector Faces................................................................................................................. 2400
8E METER AND GAUGE........................................................................................................................ 2416
Service Precaution...................................................................................................................... 2416
General Description..................................................................................................................... 2416
Meter Assembly.......................................................................................................................... 2417
General Description................................................................................................................. 2417
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights.................................................. 2417
Table for Meter/Gauge Connector Terminal Connections................................................................................ 2421
Removal............................................................................................................................. 2425
Installation........................................................................................................................ 2425
Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb, A/T Indicator Light Bulb............................................. 2425
Removal............................................................................................................................. 2425
Installation........................................................................................................................ 2425
Vehicle Speed Sensor.................................................................................................................... 2426
Removal............................................................................................................................. 2426
Installation........................................................................................................................ 2426
Fuel Tank Unit.......................................................................................................................... 2426
Removal............................................................................................................................. 2426
Installation........................................................................................................................ 2426
Main Data and Specifications............................................................................................................ 2427
8F BODY STRUCTURE......................................................................................................................... 2428
Service Precaution...................................................................................................................... 2429
Frame................................................................................................................................... 2430
General Description................................................................................................................. 2430
Frame Dimensions................................................................................................................ 2430
General Description (Bumper)............................................................................................................ 2431
Front Bumper............................................................................................................................ 2431
Parts Location...................................................................................................................... 2431
Removal............................................................................................................................. 2432
Installation........................................................................................................................ 2432
Rear Bumper............................................................................................................................. 2433
Parts Location...................................................................................................................... 2433
Removal............................................................................................................................. 2433
Installation........................................................................................................................ 2433
General Description (Sheet Metal)....................................................................................................... 2435
Engine Hood and Fender.................................................................................................................. 2435
Parts Location...................................................................................................................... 2435
Removal............................................................................................................................. 2436
Installation........................................................................................................................ 2437
Body Dimension.......................................................................................................................... 2439
General Description (Body).............................................................................................................. 2452
Instrument Panel Assembly............................................................................................................... 2452
Parts Location...................................................................................................................... 2452
Removal............................................................................................................................. 2453
Installation........................................................................................................................ 2454
Front Door Assembly..................................................................................................................... 2455
Parts Location...................................................................................................................... 2455
Removal............................................................................................................................. 2455
Installation........................................................................................................................ 2456
Rear Door Assembly...................................................................................................................... 2457
Parts Location...................................................................................................................... 2457
Removal............................................................................................................................. 2457
Installation........................................................................................................................ 2458
Front Window Regulator, Glass and Glass Run............................................................................................. 2459
Parts Location...................................................................................................................... 2459
Removal............................................................................................................................. 2460
Installation........................................................................................................................ 2462
Rear Window Regulator, Glass and Glass Run.............................................................................................. 2463
Parts Location...................................................................................................................... 2463
Removal............................................................................................................................. 2464
Installation........................................................................................................................ 2466
Rear Tailgate (Lower Side).............................................................................................................. 2467
Parts Location...................................................................................................................... 2467
Removal............................................................................................................................. 2468
Installation........................................................................................................................ 2468
Rear Hatchgate (Upper Side)............................................................................................................. 2469
Parts Location...................................................................................................................... 2469
Removal............................................................................................................................. 2470
Installation........................................................................................................................ 2470
Adjustment.......................................................................................................................... 2472
Spare Tire Carrier...................................................................................................................... 2473
Parts Location...................................................................................................................... 2473
Removal............................................................................................................................. 2473
Installation........................................................................................................................ 2473
Headlining.............................................................................................................................. 2474
Parts Location...................................................................................................................... 2474
Removal............................................................................................................................. 2475
Installation........................................................................................................................ 2475
Windshield.............................................................................................................................. 2476
Parts Location...................................................................................................................... 2476
Removal............................................................................................................................. 2477
Installation........................................................................................................................ 2477
Rear Quarter Glass...................................................................................................................... 2480
Parts Location...................................................................................................................... 2480
Removal............................................................................................................................. 2481
Installation........................................................................................................................ 2481
Main Data and Specifications............................................................................................................ 2481
Special Tools........................................................................................................................... 2484
8G SEATS.................................................................................................................................. 2485
Service Precaution...................................................................................................................... 2485
Front Seat Assembly..................................................................................................................... 2486
Front Seat Assembly and Associated Parts............................................................................................ 2486
Removal............................................................................................................................. 2486
Installation........................................................................................................................ 2486
Rear Seat Assembly...................................................................................................................... 2487
Rear Seat Assembly and Associated Parts............................................................................................. 2487
Removal............................................................................................................................. 2487
Installation........................................................................................................................ 2487
Main Data and Specifications............................................................................................................ 2488
8H SECURITY AND LOCKS..................................................................................................................... 2490
Service Precaution...................................................................................................................... 2490
Front Door Lock Assembly................................................................................................................ 2491
Front Door Lock Assembly and Associated Parts....................................................................................... 2491
Removal............................................................................................................................. 2492
Installation........................................................................................................................ 2493
Front Outside Handle.................................................................................................................... 2494
Front Outside Handle and Associated Parts........................................................................................... 2494
Removal............................................................................................................................. 2494
Installation........................................................................................................................ 2494
Rear Door Lock Assembly................................................................................................................. 2495
Rear Door Lock Assembly and Associated Parts........................................................................................ 2495
Removal............................................................................................................................. 2496
Installation........................................................................................................................ 2496
Rear Outside Handle..................................................................................................................... 2497
Rear Outside Handle and Associated Parts............................................................................................ 2497
Removal............................................................................................................................. 2497
Installation........................................................................................................................ 2497
Tailgate Lock and Hatchgate Lock........................................................................................................ 2498
Tailgate Lock, Hatchgate Lock and Associated Parts.................................................................................. 2498
Removal............................................................................................................................. 2499
Installation........................................................................................................................ 2499
Key..................................................................................................................................... 2500
Key Coding.......................................................................................................................... 2500
Key Styles.......................................................................................................................... 2500
Power Door Lock System.................................................................................................................. 2501
General Description................................................................................................................. 2501
Door Lock Key Switch................................................................................................................ 2501
Front Door Lock Actuator............................................................................................................ 2501
Rear Door Lock Actuator............................................................................................................. 2501
Tailgate Lock Actuator.............................................................................................................. 2501
Anti-Theft System....................................................................................................................... 2501
General Description................................................................................................................. 2501
Anti-Theft & Keyless Entry Controller............................................................................................... 2501
Anti-Theft Indicator................................................................................................................ 2502
Anti-Theft Horn..................................................................................................................... 2502
Engine Hood Switch.................................................................................................................. 2503
Anti-theft & Keyless Entry Control Unit/Transmitter Replacement..................................................................... 2503
8I SUN ROOF/CONVERTIBLE TOP.............................................................................................................. 2504
Service Precaution...................................................................................................................... 2504
Sun Roof Glass.......................................................................................................................... 2505
Sun Roof Glass and Associated Parts................................................................................................. 2505
Removal............................................................................................................................. 2505
Installation........................................................................................................................ 2506
Sun Roof Deflector...................................................................................................................... 2506
Removal............................................................................................................................. 2506
Installation........................................................................................................................ 2506
Sunshade................................................................................................................................ 2507
Disassembled View................................................................................................................... 2507
Removal............................................................................................................................. 2507
Installation........................................................................................................................ 2508
Sun Roof Frame Complete Assembly........................................................................................................ 2509
Sun Roof Frame Complete Assembly and Associated Parts............................................................................... 2509
Removal............................................................................................................................. 2509
Installation........................................................................................................................ 2510
Sun Roof Switch......................................................................................................................... 2510
Removal............................................................................................................................. 2510
Installation........................................................................................................................ 2510
Sun Roof Control Unit................................................................................................................... 2511
Removal............................................................................................................................. 2511
Installation........................................................................................................................ 2511
Safety Stop Switch...................................................................................................................... 2511
Removal............................................................................................................................. 2511
Installation........................................................................................................................ 2511
Limit Switch............................................................................................................................ 2512
Removal............................................................................................................................. 2512
Installation........................................................................................................................ 2512
Sun Roof Motor.......................................................................................................................... 2512
Removal............................................................................................................................. 2512
Installation........................................................................................................................ 2512
Main Data and Specifications............................................................................................................ 2513
8J EXTERIOR / INTERIOR TRIM............................................................................................................... 2514
Service Precaution...................................................................................................................... 2514
Consoles................................................................................................................................ 2515
Consoles and Associated Parts....................................................................................................... 2515
Removal............................................................................................................................. 2515
Installation........................................................................................................................ 2515
Front Door Trim Panel................................................................................................................... 2516
Front Door Trim Panel and Associated Parts.......................................................................................... 2516
Removal............................................................................................................................. 2516
Installation........................................................................................................................ 2518
Rear Door Trim Panel.................................................................................................................... 2519
Rear Door Trim Panel and Associated Parts........................................................................................... 2519
Removal............................................................................................................................. 2519
Installation........................................................................................................................ 2520
Interior Trim Panels.................................................................................................................... 2521
Interior Trim Panels and Associated Parts........................................................................................... 2521
Removal............................................................................................................................. 2521
Installation........................................................................................................................ 2522
Power Door Mirror System................................................................................................................ 2522
General Description................................................................................................................. 2522
Door Mirror Switch.................................................................................................................. 2522
Power Window System..................................................................................................................... 2523
General Description................................................................................................................. 2523
Power Window Switch Driver Seat Side................................................................................................ 2523
Power Window Motor.................................................................................................................. 2524
Sec.9 RESTRAINTS.............................................................................................................................. 2525
9A SEAT BELT SYSTEM....................................................................................................................... 2525
Service Precaution...................................................................................................................... 2525
Front Seat Belt......................................................................................................................... 2526
Front Seat Belt and Associated Parts................................................................................................ 2526
Removal............................................................................................................................. 2526
Installation........................................................................................................................ 2526
Rear Seat Belt.......................................................................................................................... 2527
Rear Seat Belt and Associated Parts................................................................................................. 2527
Removal............................................................................................................................. 2527
Installation........................................................................................................................ 2528
Front Seat Buckle Assembly.............................................................................................................. 2529
Removal............................................................................................................................. 2529
Installation........................................................................................................................ 2529
Main Data and Specifications............................................................................................................ 2530
9J SUPPLEMENTAL RESTRAINT SYSTEM.......................................................................................................... 2531
Service Precaution...................................................................................................................... 2532
General Description..................................................................................................................... 2532
Restraint Devices................................................................................................................... 2532
System Description.................................................................................................................. 2533
SRS Component and Wiring Location View.................................................................................................. 2534
Component Description................................................................................................................... 2534
SDM (Sensing and Diagnostic Module)................................................................................................. 2534
"Air Bag" Warning Lamp.............................................................................................................. 2535
SRS Coil Assembly................................................................................................................... 2535
Air Bag Assemblies.................................................................................................................. 2535
Steering Column..................................................................................................................... 2536
Knee Bolster........................................................................................................................ 2536
Definition.............................................................................................................................. 2536
Diagnosis............................................................................................................................... 2537
Diagnostic Trouble Codes............................................................................................................ 2537
Scan Tool Diagnostics............................................................................................................... 2537
Use of Special Tools................................................................................................................ 2538
SRS Connector Body Face Views........................................................................................................... 2538
Repairs and Inspections Required After an Accident.................................................................................. 2538
Accident With Deployment-Component Replacement and Inspections...................................................................... 2539
Accident With or Without Deployment-Component Inspection............................................................................ 2539
SDM Replacement Guidelines.......................................................................................................... 2539
Wiring Damage....................................................................................................................... 2539
SRS Connector (Plastic Body And Terminal Metal Pin) Damage.......................................................................... 2539
SRS Wire Pigtail Damage............................................................................................................. 2539
On-Vehicle Service...................................................................................................................... 2539
Service Precautions................................................................................................................. 2539
Disabling The SRS................................................................................................................... 2539
Enabling The SRS.................................................................................................................... 2539
Handling / Installation / Diagnosis................................................................................................. 2540
Air Bag Assembly Handling / Shipping / Scrapping........................................................................................ 2540
Live (Undeployed) Air Bag Assembly.................................................................................................. 2540
Air Bag Assembly Shipping Procedure For Live (Undeployed) Air Bag Assemblies........................................................ 2541
Deployed Air Bag Assembly........................................................................................................... 2541
Air Bag Assembly Scrapping Procedure................................................................................................ 2541
Deployment Outside Vehicle (Driver Air Bag Assembly)................................................................................ 2541
Deployment Outside Vehicle (Passenger Air Bag Assembly)............................................................................. 2543
Deployment Inside Vehicle (Vehicle Scrapping Procedure)............................................................................. 2545
Deployed Air Bag Assembly Handling.................................................................................................. 2548
Special Tools........................................................................................................................... 2548
J-41433 SRS Driver/Passenger Load Tool.............................................................................................. 2548
J-39200 DVM......................................................................................................................... 2549
Scan Tool........................................................................................................................... 2549
J-35616-A Connector Test Adapter Kit................................................................................................ 2549
J-42986 SRS Deployment Tool......................................................................................................... 2549
J-42987 SRS Adapter For Load Tool................................................................................................... 2550
J-41497 SRS Deployment Fixture...................................................................................................... 2550
Tech 2 Scan Tool.................................................................................................................... 2551
Service Precaution...................................................................................................................... 2554
Disabling The SRS................................................................................................................... 2554
Enabling The SRS.................................................................................................................... 2554
Handling / Installation / Diagnosis................................................................................................. 2554
Inspections Required After An Accident.............................................................................................. 2554
Sensing and Diagnostic Module (SDM)..................................................................................................... 2555
Service Precautions................................................................................................................. 2555
Removal............................................................................................................................. 2555
Installation........................................................................................................................ 2556
Driver Air Bag Assembly................................................................................................................. 2556
Service Precautions................................................................................................................. 2556
Removal............................................................................................................................. 2556
Installation........................................................................................................................ 2557
Steering Wheel.......................................................................................................................... 2557
Service Precautions................................................................................................................. 2557
Removal............................................................................................................................. 2557
Installation........................................................................................................................ 2558
SRS Coil Assembly....................................................................................................................... 2559
Service Precaution.................................................................................................................. 2559
Removal............................................................................................................................. 2559
Installation........................................................................................................................ 2559
Steering Column......................................................................................................................... 2561
Service Precaution.................................................................................................................. 2561
Removal............................................................................................................................. 2561
Installation........................................................................................................................ 2562
Passenger Air Bag Assembly.............................................................................................................. 2563
Service Precaution.................................................................................................................. 2563
Removal............................................................................................................................. 2563
Installation........................................................................................................................ 2563
9J1 SRS CONTROL SYSTEM..................................................................................................................... 2564
Service Precaution...................................................................................................................... 2564
Diagnostic Information.................................................................................................................. 2565
Diagnostic Procedures............................................................................................................... 2565
Diagnostic Codes.................................................................................................................... 2565
How To Read Trouble Codes........................................................................................................... 2565
How To Clear Trouble Codes.......................................................................................................... 2565
Scan Tool Diagnostics............................................................................................................... 2565
Basic Knowledge Required............................................................................................................ 2565
Basic Electrical Circuits........................................................................................................... 2565
"Flash Code" Diagnostics............................................................................................................ 2565
System Schematic........................................................................................................................ 2566
SRS Diagnostic System Check............................................................................................................. 2567
SRS Diagnostic System Check............................................................................................................. 2568
Chart A SDM Integrity Check............................................................................................................. 2569
Chart B "AIR BAG" Warning Lamp Comes "ON" Steady........................................................................................ 2571
Chart C "AIR BAG" Warning Lamp Does Not Comes "ON" Steady............................................................................... 2573
DTC 15 Passenger Deployment Loop Resistance High........................................................................................ 2576
DTC 16 Passenger Deployment Loop Resistance Low......................................................................................... 2579
DTC 17 Passenger Deployment Loop Open................................................................................................... 2582
DTC 18 Passenger Deployment Loop Short To Ground........................................................................................ 2584
DTC 19 Passenger Deployment Loop Short To Voltage....................................................................................... 2586
DTC 21 Driver Deployment Loop Resistance High........................................................................................... 2588
DTC 22 Driver Deployment Loop Resistance Low............................................................................................ 2591
DTC 24 Driver Deployment Loop Short To Ground........................................................................................... 2594
DTC 25 Driver Deployment Loop Short To Voltage.......................................................................................... 2596
DTC 26 Driver Deployment Loop Open...................................................................................................... 2599
DTC 51 Deployment Event Commanded....................................................................................................... 2602
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range.................................................. 2604
DTC 61 Warning Lamp Circuit Failure..................................................................................................... 2606
DTC 71 Internal SDM Fault............................................................................................................... 2608
Sec.10 CONTROL SYSTEM.......................................................................................................................... 2610
10A CRUISE CONTROL SYSTEM.................................................................................................................. 2610
Service Precaution...................................................................................................................... 2610
General Description..................................................................................................................... 2610
Diagnosis............................................................................................................................... 2611
Brake Switch............................................................................................................................ 2611
Removal and Installation............................................................................................................ 2611
Adjustment.......................................................................................................................... 2611
Clutch Switch........................................................................................................................... 2612
Removal and Installation............................................................................................................ 2612
Adjustment.......................................................................................................................... 2612
Cruise Control Unit..................................................................................................................... 2612
Removal............................................................................................................................. 2612
Installation........................................................................................................................ 2612
Cruise Actuator......................................................................................................................... 2613
Actuator Cable Diagram.............................................................................................................. 2613
Removal............................................................................................................................. 2613
Installation........................................................................................................................ 2613
Adjustment.......................................................................................................................... 2613
Mode Switch............................................................................................................................. 2614
Removal and Installation............................................................................................................ 2614
Cruise Control Main Switch.............................................................................................................. 2614
Removal............................................................................................................................. 2614
Installation........................................................................................................................ 2614
Cruise Control Switch (Combination Switch).............................................................................................. 2615
Removal and Installation............................................................................................................ 2615
(UA) AMIGO.......................................................................................................................................... 2616
Sec.0 GENERAL INFORMATION..................................................................................................................... 2617
0A GENERAL INFORMATION.................................................................................................................... 2617
General Repair Instruction.............................................................................................................. 2617
Illustration Arrows..................................................................................................................... 2618
Identification.......................................................................................................................... 2619
Theft Prevention Standard............................................................................................................... 2621
Lifting Instructions.................................................................................................................... 2626
Standard Bolts Torque Specifications.................................................................................................... 2628
Abbreviations Charts.................................................................................................................... 2629
Service Parts Identification Plate...................................................................................................... 2630
0B MAINTENANCE AND LUBRICATION............................................................................................................ 2631
Maintenance Schedule List............................................................................................................... 2631
Explanation of Complete Vehicle Maintenance Schedule.................................................................................... 2635
Recommended Fluids and Lubricants................................................................................................... 2638
Lubricant Viscosity Chart............................................................................................................... 2639
Recommended Liquid Gasket........................................................................................................... 2641
Recommended Thread Locking Agents................................................................................................... 2642
Maintenance Service Data................................................................................................................ 2643
Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................................................ 2644
1A HVAC SYSTEMS........................................................................................................................... 2644
Sec.2 STEERING................................................................................................................................ 2645
2A POWER-ASSISTED STEERING SYSTEM......................................................................................................... 2645
Sec.3 SUSPENSION.............................................................................................................................. 2646
3C FRONT SUSPENSION....................................................................................................................... 2646
3D REAR SUSPENSION........................................................................................................................ 2646
3E WHEEL AND TIRE SYSTEM.................................................................................................................. 2646
Sec.4 DRIVELINE/AXLE.......................................................................................................................... 2648
4A1 DIFFERENTIAL (FRONT)................................................................................................................... 2648
Main Data And Specifications............................................................................................................ 2649
4A2 DIFFERENTIAL (REAR).................................................................................................................... 2650
Main Data And Specifications............................................................................................................ 2651
4B DRIVELINE CONTROL SYSTEM............................................................................................................... 2647
4C DRIVE SHAFT SYSTEM..................................................................................................................... 2652
Service Precaution...................................................................................................................... 2653
Front Propeller Shaft................................................................................................................... 2654
General Description................................................................................................................. 2654
Diagnosis of Propeller Shaft and Universal Joint.................................................................................... 2656
Front Propeller Shaft and Associated Parts.......................................................................................... 2657
Removal............................................................................................................................. 2657
Installation........................................................................................................................ 2657
Slip Joint Disassembly.............................................................................................................. 2658
Universal Joint Disassembly(Single Cardan Type)..................................................................................... 2659
Universal Joint Disassembly (Double Cardan Type).................................................................................... 2661
Inspection and Repair............................................................................................................... 2662
Universal Joint Reassembly(Single Cardan Type)...................................................................................... 2664
Universal Joint Reassembly (Double Cardan Type)..................................................................................... 2665
Slip Joint Reassembly............................................................................................................... 2667
Main Data And Specifications........................................................................................................ 2668
Rear Propeller Shaft.................................................................................................................... 2669
General Description................................................................................................................. 2669
Diagnosis of Propeller Shaft and Universal Joint.................................................................................... 2671
Rear Propeller Shaft and Associated Parts........................................................................................... 2672
Removal............................................................................................................................. 2672
Installation........................................................................................................................ 2672
Slip Joint Disassembly (6VD1 Model and X22SE 4×4 Model Only)........................................................................ 2673
Universal Joint Disassembly......................................................................................................... 2674
Inspection.......................................................................................................................... 2676
Universal Joint Reassembly.......................................................................................................... 2677
Slip Joint Reassembly (6VD1 Model and X22SE 4×4 Model Only)......................................................................... 2678
Main Data and Specifications........................................................................................................ 2679
4D TRANSFER CASE.......................................................................................................................... 2647
Sec.5 BRAKE CONTROL SYSTEM.................................................................................................................... 2680
5A BRAKE CONTROL SYSTEM................................................................................................................... 2680
5B ANTI-LOCK BRAKE SYSTEM................................................................................................................. 2680
5C POWER-ASSISTED BRAKE SYSTEM............................................................................................................ 2680
5D1 PARKING BRAKE SYSTEM (4x4 Model)....................................................................................................... 2680
5D2 PARKING BRAKE SYSTEM (4x2 Model)....................................................................................................... 2680
Sec.6 ENGINE.................................................................................................................................... 2681
X22SE 2.2L ENGINE........................................................................................................................... 2681
6A ENGINE MECHANICAL (X22SE 2.2L)..................................................................................................... 2681
6B ENGINE COOLING (X22SE 2.2L)........................................................................................................ 2681
6C ENGINE FUEL (X22SE 2.2L)........................................................................................................... 2682
Service Precaution.................................................................................................................. 2682
General Description................................................................................................................. 2683
Fuel Metering....................................................................................................................... 2684
Fuel Filter......................................................................................................................... 2685
Fuel Filter and Associated Parts................................................................................................ 2685
Removal......................................................................................................................... 2685
Inspection...................................................................................................................... 2685
Installation.................................................................................................................... 2685
Inspection...................................................................................................................... 2685
In-Tank Fuel Filter............................................................................................................. 2685
Fuel Pump Flow Test............................................................................................................. 2686
Fuel Pump Relay..................................................................................................................... 2687
General Description............................................................................................................. 2687
Fuel Tank........................................................................................................................... 2687
Fuel Tank and Associated Parts.................................................................................................. 2687
Removal......................................................................................................................... 2688
Installation.................................................................................................................... 2688
Fuel Gauge Unit..................................................................................................................... 2688
Removal and Installation........................................................................................................ 2688
Fuel Tube / Quick-Connector Fittings................................................................................................ 2689
Precautions..................................................................................................................... 2689
Cautions During Work............................................................................................................ 2689
Removal......................................................................................................................... 2689
Reuse of Quick-Connector........................................................................................................ 2691
Assembling Advice............................................................................................................... 2691
Fuel Filler Cap..................................................................................................................... 2692
General Description............................................................................................................. 2692
Inspection...................................................................................................................... 2692
Fuel Pump........................................................................................................................... 2693
Fuel Pump and Associated Parts.................................................................................................. 2693
Removal......................................................................................................................... 2693
Installation.................................................................................................................... 2694
Main Data and Specifications........................................................................................................ 2694
Special Tool........................................................................................................................ 2694
6D1 ENGINE ELECTRICAL (X22SE 2.2L)..................................................................................................... 2681
6D2 IGNITION SYSTEM (X22SE 2.2L)....................................................................................................... 2681
6D3 STARTING AND CHARGING SYSTEM (X22SE 2.2L).......................................................................................... 2681
6E1 2.2L ENGINE DRIVEABILITY AND EMISSIONS............................................................................................. 2681
6F ENGINE EXHAUST (X22SE 2.2L)........................................................................................................ 2695
Service Precaution.................................................................................................................. 2695
General Description................................................................................................................. 2696
Front Exhaust Pipe.................................................................................................................. 2697
Front Exhaust Pipe and Associated Parts......................................................................................... 2697
Removal......................................................................................................................... 2697
Installation.................................................................................................................... 2697
Exhaust Silencer.................................................................................................................... 2698
Exhaust Silencer and Associated Parts........................................................................................... 2698
Removal......................................................................................................................... 2698
Installation.................................................................................................................... 2698
Rear Exhaust pipe................................................................................................................... 2699
Rear Exhaust pipe and Associated Parts.......................................................................................... 2699
Removal......................................................................................................................... 2699
Installation.................................................................................................................... 2699
Main Data and Specifications........................................................................................................ 2700
6G ENGINE LUBRICATION (X22SE 2.2L).................................................................................................... 2681
6H ENGINE SPEED CONTROL SYSTEM (X22SE 2.2L)........................................................................................... 2681
6J INDUCTION (X22SE 2.2L).............................................................................................................. 2681
6VD1 3.2L ENGINE............................................................................................................................ 2701
6A ENGINE MECHANICAL (6VD1 3.2L)...................................................................................................... 2701
6B ENGINE COOLING (6VD1 3.2L)......................................................................................................... 2701
6C ENGINE FUEL (6VD1 3.2L)............................................................................................................ 2702
Service Precaution.................................................................................................................. 2702
General Description................................................................................................................. 2703
Fuel Metering....................................................................................................................... 2704
Fuel Filter......................................................................................................................... 2705
Removal......................................................................................................................... 2705
Inspection...................................................................................................................... 2705
Installation.................................................................................................................... 2705
Inspection...................................................................................................................... 2706
In-Tank Fuel Filter............................................................................................................. 2706
Fuel Pump Flow Test............................................................................................................. 2706
Fuel Pump Relay..................................................................................................................... 2706
General Description............................................................................................................. 2706
Fuel Tank........................................................................................................................... 2707
Fuel Tank and Associated Parts.................................................................................................. 2707
Removal......................................................................................................................... 2707
Installation.................................................................................................................... 2708
Fuel Tube / Quick-Connector Fittings................................................................................................ 2708
Precautions..................................................................................................................... 2708
Cautions During Work............................................................................................................ 2708
Removal......................................................................................................................... 2708
Reuse of Quick-Connector........................................................................................................ 2710
Assembling Advice............................................................................................................... 2710
Fuel Gauge Unit..................................................................................................................... 2711
Removal and Installation........................................................................................................ 2711
Fuel Pump........................................................................................................................... 2711
Fuel Pump and Associated Parts.................................................................................................. 2711
Removal......................................................................................................................... 2712
Installation.................................................................................................................... 2712
Fuel Filler Cap..................................................................................................................... 2712
General Description............................................................................................................. 2712
Inspection...................................................................................................................... 2712
Main Data and Specifications........................................................................................................ 2713
Special Tool........................................................................................................................ 2713
6D1 ENGINE ELECTRICAL (6VD1 3.2L)...................................................................................................... 2701
6D2 IGNITION SYSTEM (6VD1 3.2L)........................................................................................................ 2701
6D3 STARTING AND CHARGING SYSTEM (6VD1 3.2L)........................................................................................... 2714
Service Precaution.................................................................................................................. 2714
Starting System..................................................................................................................... 2715
General Description............................................................................................................. 2715
Diagnosis....................................................................................................................... 2717
Starter............................................................................................................................. 2718
Removal......................................................................................................................... 2718
Installation.................................................................................................................... 2718
Disassembled View............................................................................................................... 2719
Disassembly..................................................................................................................... 2720
Inspection and Repair........................................................................................................... 2722
Reassembly...................................................................................................................... 2726
Main Data and Specifications.................................................................................................... 2728
Charging System..................................................................................................................... 2731
General Description............................................................................................................. 2731
General On-Vehicle Inspection................................................................................................... 2731
Generator........................................................................................................................... 2732
Removal......................................................................................................................... 2732
Inspection...................................................................................................................... 2732
Installation.................................................................................................................... 2733
Disassembled View............................................................................................................... 2733
Disassembly..................................................................................................................... 2734
Inspection and Repair........................................................................................................... 2735
Reassembly...................................................................................................................... 2737
Bench Test...................................................................................................................... 2738
Main Data and Specifications.................................................................................................... 2739
6E1 3.2L ENGINE DRIVEABILITY AND EMISSIONS............................................................................................. 2701
6F ENGINE EXHAUST (6VD1 3.2L)......................................................................................................... 2740
Service Precaution.................................................................................................................. 2740
General Description................................................................................................................. 2741
Three Way Catalytic Converter RH and Forked Exhaust Pipe............................................................................ 2742
Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts................................................... 2742
Removal......................................................................................................................... 2742
Installation.................................................................................................................... 2742
Three Way Catalytic Converter LH and Forked Exhaust Pipe............................................................................ 2743
Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated Parts................................................... 2743
Removal......................................................................................................................... 2743
Installation.................................................................................................................... 2743
Forked Exhaust Pipe................................................................................................................. 2744
Forked Exhaust Pipe and Associated Parts........................................................................................ 2744
Removal......................................................................................................................... 2744
Installation.................................................................................................................... 2744
Exhaust Silencer.................................................................................................................... 2745
Exhaust Silencer and Associated Parts........................................................................................... 2745
Removal......................................................................................................................... 2745
Installation.................................................................................................................... 2745
Rear Exhaust pipe................................................................................................................... 2746
Rear Exhaust pipe and Associated Parts.......................................................................................... 2746
Removal......................................................................................................................... 2746
Installation.................................................................................................................... 2746
Main Data and Specifications........................................................................................................ 2747
6G ENGINE LUBRICATION (6VD1 3.2L)..................................................................................................... 2701
6H ENGINE SPEED CONTROL SYSTEM (6VD1 3.2L)............................................................................................ 2701
6J INDUCTION (6VD1 3.2L).............................................................................................................. 2701
Sec.7 AUTOMATIC TRANSMISSION.................................................................................................................. 2748
7B MANUAL TRANSMISSION MUA 5C (4X2, 4X4) AND TREMEC T5R(4X2).............................................................................. 2748
7C CLUTCH................................................................................................................................. 2748
Sec.8 BODY AND ACCESSORIES.................................................................................................................... 2750
8A LIGHTING SYSTEM........................................................................................................................ 2750
Service Precaution...................................................................................................................... 2750
Headlight Bulb.......................................................................................................................... 2751
Headlight Assembly...................................................................................................................... 2751
Headlight Adjustment................................................................................................................ 2752
Fog Light Bulb.......................................................................................................................... 2752
Fog Light Assembly...................................................................................................................... 2753
Fog Light Adjustment................................................................................................................ 2753
Side Marker Light Bulb.................................................................................................................. 2753
Front Combination Light Assembly........................................................................................................ 2754
Taillight Bulb.......................................................................................................................... 2754
License Plate Light Bulb................................................................................................................ 2755
Stoplight Bulb.......................................................................................................................... 2755
High Mounted Stoplight Assembly (Soft Top Model)........................................................................................ 2756
High Mounted Stoplight Bulb (Soft Top Model)............................................................................................ 2756
High Mounted Stoplight Assembly (Resin Top Model)....................................................................................... 2757
High Mounted Stoplight Bulb (Resin Top Model)........................................................................................... 2757
Backup Light Bulb....................................................................................................................... 2758
Front Turn Signal Light Bulb............................................................................................................ 2758
Rear Turn Signal Light Bulb............................................................................................................. 2759
Dome Light Bulb......................................................................................................................... 2759
Courtesy Light Bulb..................................................................................................................... 2760
Spotlight Bulb.......................................................................................................................... 2760
Luggage Room Light Bulb (Resin Top Model)............................................................................................... 2761
HVAC Bezel Illumination Light Bulb...................................................................................................... 2761
Shift Lever Illumination Light Bulb (A/T)............................................................................................... 2762
Starter Switch.......................................................................................................................... 2762
Lighting Switch (Combination Switch).................................................................................................... 2763
Dimmer-Passing Switch (Combination Switch).............................................................................................. 2763
Door Switch............................................................................................................................. 2763
Key Remind Switch (Starter Switch)...................................................................................................... 2764
Hazard Warning Light Switch............................................................................................................. 2764
Stoplight Switch........................................................................................................................ 2764
Backup Light Switch (M/T)............................................................................................................... 2765
Turn Signal Light Switch (Combination Switch)........................................................................................... 2765
Illumination Controller................................................................................................................. 2765
Light and Bulb Specifications........................................................................................................... 2766
8B WIPER / WASHER SYSTEM.................................................................................................................. 2768
Service Precaution...................................................................................................................... 2768
Windshield Wiper/Washer System.......................................................................................................... 2769
General Description................................................................................................................. 2769
Windshield Wiper And Washer Switch...................................................................................................... 2769
Removal and Installation............................................................................................................ 2769
Windshield Wiper Motor.................................................................................................................. 2769
Removal............................................................................................................................. 2769
Installation........................................................................................................................ 2769
Windshield Washer Motor................................................................................................................. 2770
Removal............................................................................................................................. 2770
Installation........................................................................................................................ 2770
Windshield Washer Spray Pattern......................................................................................................... 2771
Windshield Wiper Linkage................................................................................................................ 2772
Windshield Wiper Linkage and Associated Parts....................................................................................... 2772
Removal............................................................................................................................. 2772
Installation........................................................................................................................ 2772
Windshield Wiper Arm/Blade.............................................................................................................. 2773
Removal............................................................................................................................. 2773
Installation........................................................................................................................ 2773
Windshield Wiper Blade Rubber........................................................................................................... 2774
Removal............................................................................................................................. 2774
Installation........................................................................................................................ 2774
Rear Wiper/Washer System (Resin Top Model).............................................................................................. 2775
General Description................................................................................................................. 2775
Rear Wiper and Washer Switch (Resin Top Model).......................................................................................... 2775
Removal............................................................................................................................. 2775
Installation........................................................................................................................ 2775
Rear Wiper Motor (Resin Top Model)...................................................................................................... 2776
Removal............................................................................................................................. 2776
Installation........................................................................................................................ 2776
Rear Washer Motor (Resin Top Model)..................................................................................................... 2776
Removal............................................................................................................................. 2776
Installation........................................................................................................................ 2776
Alarm and Relay Control Unit............................................................................................................ 2777
Removal............................................................................................................................. 2777
Installation........................................................................................................................ 2777
Rear Wiper Arm/Blade (Resin Top Model).................................................................................................. 2777
Removal............................................................................................................................. 2777
Installation........................................................................................................................ 2777
Rear Washer Nozzle (Resin Top Model).................................................................................................... 2778
Removal............................................................................................................................. 2778
Installation........................................................................................................................ 2778
Rear Washer Spray Pattern........................................................................................................... 2778
Rear Wiper Blade Rubber (Resin Top Model)............................................................................................... 2778
Removal............................................................................................................................. 2778
Installation........................................................................................................................ 2779
Main Data and Specifications............................................................................................................ 2779
8C ENTERTAINMENT.......................................................................................................................... 2780
Service Precaution...................................................................................................................... 2780
Cigarette Lighter....................................................................................................................... 2781
General Description................................................................................................................. 2781
Removal............................................................................................................................. 2781
Installation........................................................................................................................ 2781
Digital Clock........................................................................................................................... 2781
Removal............................................................................................................................. 2781
Installation........................................................................................................................ 2782
Rod Type Antenna........................................................................................................................ 2782
Removal............................................................................................................................. 2782
Installation........................................................................................................................ 2782
Accessory Socket........................................................................................................................ 2783
Front Accessory Socket.............................................................................................................. 2783
Rear Accessory Socket............................................................................................................... 2783
Radio................................................................................................................................... 2784
Removal............................................................................................................................. 2784
Installation........................................................................................................................ 2784
Speaker................................................................................................................................. 2785
Front Speaker....................................................................................................................... 2785
Tweeter Assembly.................................................................................................................... 2785
Rear Speaker........................................................................................................................ 2785
Horn.................................................................................................................................... 2786
Removal............................................................................................................................. 2786
Installation........................................................................................................................ 2786
8D WIRING SYSTEM.......................................................................................................................... 2787
Service Precaution...................................................................................................................... 2789
Main Data and Specifications............................................................................................................ 2790
Relay Location.......................................................................................................................... 2798
Diode Location.......................................................................................................................... 2800
Grounding Point......................................................................................................................... 2802
Cable Harness Routing................................................................................................................... 2806
Stoplight............................................................................................................................... 2809
General Description................................................................................................................. 2809
Circuit Diagram..................................................................................................................... 2810
Parts Location...................................................................................................................... 2811
Diagnosis........................................................................................................................... 2812
Horn.................................................................................................................................... 2814
General Description................................................................................................................. 2814
Circuit Diagram..................................................................................................................... 2815
Parts Location...................................................................................................................... 2816
Diagnosis........................................................................................................................... 2817
Dome Light, Luggage Room Light, Courtesy Light, Map Light, Seat Belt Switch and Warning Buzzer.......................................... 2819
General Description................................................................................................................. 2819
Circuit Diagram..................................................................................................................... 2820
Parts Location...................................................................................................................... 2824
Diagnosis........................................................................................................................... 2825
Power Door Lock......................................................................................................................... 2826
General Description................................................................................................................. 2826
Circuit Diagram..................................................................................................................... 2827
Parts Location...................................................................................................................... 2831
Diagnosis........................................................................................................................... 2832
Rear Wiper/Washer....................................................................................................................... 2834
General Description................................................................................................................. 2834
Circuit Diagram..................................................................................................................... 2835
Parts Location...................................................................................................................... 2838
Diagnosis........................................................................................................................... 2839
Rear Defogger/Mirror Defogger........................................................................................................... 2845
General Description................................................................................................................. 2845
Circuit Diagram..................................................................................................................... 2846
Parts Location...................................................................................................................... 2849
Diagnosis........................................................................................................................... 2850
Audio................................................................................................................................... 2852
General Description................................................................................................................. 2852
Circuit Diagram..................................................................................................................... 2853
Parts Location...................................................................................................................... 2854
Cigarette Lighter, and Digital Clock Accessory Socket................................................................................... 2855
General Description................................................................................................................. 2855
Circuit Diagram..................................................................................................................... 2856
Parts Location...................................................................................................................... 2857
Diagnosis........................................................................................................................... 2858
Keyless Entry and Anti-Theft System..................................................................................................... 2859
General Description................................................................................................................. 2859
Circuit Diagram..................................................................................................................... 2860
Parts Location...................................................................................................................... 2865
Diagnosis........................................................................................................................... 2866
ID Code Registration.................................................................................................................... 2871
Answer Back (Anti-theft Horn Operation) Change Mode..................................................................................... 2874
8E METER AND GAUGE........................................................................................................................ 2749
8F BODY STRUCTURE......................................................................................................................... 2875
Service Precaution...................................................................................................................... 2876
Frame................................................................................................................................... 2877
General Description................................................................................................................. 2877
Frame Dimensions.................................................................................................................... 2877
Body Dimension.......................................................................................................................... 2878
Rear Tailgate (Lower Side).............................................................................................................. 2887
Parts Location...................................................................................................................... 2887
Removal............................................................................................................................. 2888
Installation........................................................................................................................ 2888
Rear Hatchgate (Upper Side)............................................................................................................. 2889
Parts Location (Resin Top Model).................................................................................................... 2889
Removal............................................................................................................................. 2890
Installation........................................................................................................................ 2890
Headlining.............................................................................................................................. 2891
Parts Location...................................................................................................................... 2891
Removal............................................................................................................................. 2892
Installation........................................................................................................................ 2892
Side Window Glass....................................................................................................................... 2893
Parts Location...................................................................................................................... 2893
Removal............................................................................................................................. 2893
Installation........................................................................................................................ 2893
Rear Quarter Glass...................................................................................................................... 2894
Parts Location (Resin Top Model).................................................................................................... 2894
Removal............................................................................................................................. 2894
Installation........................................................................................................................ 2894
8G SEATS.................................................................................................................................. 2896
Service Precaution...................................................................................................................... 2896
Rear Seat Assembly...................................................................................................................... 2897
Rear Seat Assembly and Associated Parts............................................................................................. 2897
Removal............................................................................................................................. 2897
Installation........................................................................................................................ 2898
Main Data and Specifications............................................................................................................ 2899
8H SECURITY AND LOCKS..................................................................................................................... 2900
Service Precaution...................................................................................................................... 2901
Tailgate Lock........................................................................................................................... 2902
Tailgate Lock and Associated Parts.................................................................................................. 2902
Removal............................................................................................................................. 2903
Installation........................................................................................................................ 2903
Main Data and Specifications............................................................................................................ 2903
8I SUN ROOF/CONVERTIBLE TOP............................................................................................................... 2904
Service Precaution...................................................................................................................... 2904
Sun Roof Glass.......................................................................................................................... 2905
Sun Roof Glass and Associated Parts................................................................................................. 2905
Removal............................................................................................................................. 2905
Installation........................................................................................................................ 2906
Sun Roof Deflector...................................................................................................................... 2907
Parts Location...................................................................................................................... 2907
Removal............................................................................................................................. 2907
Installation........................................................................................................................ 2907
Soft Top Assembly....................................................................................................................... 2908
Soft Top Assembly and Associated Parts.............................................................................................. 2908
Removal............................................................................................................................. 2909
Installation........................................................................................................................ 2909
Resin Top Assembly...................................................................................................................... 2910
Resin Top Assembly and Associated Parts............................................................................................. 2910
Removal............................................................................................................................. 2910
Installation........................................................................................................................ 2911
Seat Belt Cross Bar Assembly............................................................................................................ 2912
Seat Belt Cross Bar Assembly and Associated......................................................................................... 2912
Removal............................................................................................................................. 2912
Installation........................................................................................................................ 2913
Main Data and Specifications............................................................................................................ 2914
8J EXTERIOR / INTERIOR TRIM............................................................................................................... 2915
Service Precaution...................................................................................................................... 2915
Interior Trim Panels.................................................................................................................... 2916
Interior Trim Panels and Associated Parts........................................................................................... 2916
Removal............................................................................................................................. 2916
Installation........................................................................................................................ 2917
Sec.9 RESTRAINTS.............................................................................................................................. 2919
9A SEAT BELT SYSTEM....................................................................................................................... 2919
Service Precaution...................................................................................................................... 2919
Front Seat Belt......................................................................................................................... 2920
Front Seat Belt and Associated Parts................................................................................................ 2920
Removal............................................................................................................................. 2920
Installation........................................................................................................................ 2921
Rear Seat Belt.......................................................................................................................... 2922
Rear Seat Belt and Associated Parts................................................................................................. 2922
Removal............................................................................................................................. 2922
Installation........................................................................................................................ 2923
Rear Center Seat Belt / Buckle Assembly................................................................................................. 2924
Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................ 2924
Removal............................................................................................................................. 2924
Installation........................................................................................................................ 2924
Main Data and Specifications............................................................................................................ 2925
9J SUPPLEMENTAL RESTRAINT SYSTEM.......................................................................................................... 2918
9J1 SRS CONTROL SYSTEM..................................................................................................................... 2918
Sec.10 CRUISE CONTROL SYSTEM................................................................................................................... 2926
10A CRUISE CONTROL SYSTEM.................................................................................................................. 2926
(VX) VEHICROSS...................................................................................................................................... 5231
Sec.0 GENERAL INFORMATION..................................................................................................................... 5232
0A GENERAL INFORMATION.................................................................................................................... 5232
General Repair Instruction.............................................................................................................. 5232
Illustration Arrows..................................................................................................................... 5233
Identification.......................................................................................................................... 5234
Theft Prevention Standard............................................................................................................... 5236
Lifting Instructions.................................................................................................................... 5240
Standard Bolts Torque Specifications.................................................................................................... 5243
Abbreviations Charts.................................................................................................................... 5244
Service Parts Identification Plate...................................................................................................... 5245
0B MAINTENANCE AND LUBRICATION............................................................................................................ 5246
Maintenance Schedule List............................................................................................................... 5246
Explanation of Complete Vehicle Maintenance Schedule.................................................................................... 5249
Recommended Fluids and Lubricants................................................................................................... 5252
Lubricant Viscosity Chart............................................................................................................... 5253
Recommended Liquid Gasket........................................................................................................... 5254
Recommended Thread Locking Agents................................................................................................... 5255
Maintenance Service Data................................................................................................................ 5256
Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................................................ 5257
1A HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....................................................................................... 5257
Service Precaution...................................................................................................................... 5258
Heating and Ventilation System.......................................................................................................... 5258
General Description................................................................................................................. 5258
Wiring Diagram...................................................................................................................... 5262
Diagnosis........................................................................................................................... 5263
Individual Inspection............................................................................................................... 5267
Heater.................................................................................................................................. 5269
Heater Unit and Associated Parts.................................................................................................... 5269
Removal............................................................................................................................. 5269
Installation........................................................................................................................ 5270
Heater Core and / or Mode Door.......................................................................................................... 5270
Disassembled View................................................................................................................... 5270
Removal............................................................................................................................. 5271
Inspection.......................................................................................................................... 5271
Installation........................................................................................................................ 5271
Heater Mode Control Link Unit........................................................................................................... 5272
Disassembled View................................................................................................................... 5272
Removal............................................................................................................................. 5272
Installation........................................................................................................................ 5273
Heater Temperature Control Link Unit.................................................................................................... 5273
Disassembled View................................................................................................................... 5273
Removal............................................................................................................................. 5273
Installation........................................................................................................................ 5273
Blower Assembly......................................................................................................................... 5274
Blower Assembly and Associated Parts................................................................................................ 5274
Removal............................................................................................................................. 5274
Installation........................................................................................................................ 5275
Blower Link Unit and / or Mode door..................................................................................................... 5275
Disassembled View................................................................................................................... 5275
Removal............................................................................................................................. 5275
Installation........................................................................................................................ 5276
Blower Motor............................................................................................................................ 5277
Blower Motor and Associated Parts................................................................................................... 5277
Removal............................................................................................................................. 5277
Installation........................................................................................................................ 5277
Defroster Nozzle and Ventilation Duct................................................................................................... 5278
Defroster Nozzle, Ventilation Duct and Associated Parts............................................................................. 5278
Removal............................................................................................................................. 5278
Installation........................................................................................................................ 5279
Control Lever Assembly and / or Control Cable........................................................................................... 5279
Control Lever Assembly, Control Cable and Associated Parts.......................................................................... 5279
Removal............................................................................................................................. 5280
Installation........................................................................................................................ 5281
Heater Bezel Illumination Bulb.......................................................................................................... 5282
Heater Bezel Illumination Bulb and Associated Parts................................................................................. 5282
Removal............................................................................................................................. 5282
Installation........................................................................................................................ 5282
Resistor................................................................................................................................ 5283
Resistor and Associated Parts....................................................................................................... 5283
Removal............................................................................................................................. 5283
Installation........................................................................................................................ 5283
Air Conditioning System................................................................................................................. 5284
General Description................................................................................................................. 5284
Air Conditioning Refrigerant Cycle Construction..................................................................................... 5285
Wiring Diagram...................................................................................................................... 5292
Connector List...................................................................................................................... 5296
Diagnosis........................................................................................................................... 5298
Checking The Refrigerant System With Manifold Gauge................................................................................. 5299
Magnetic Clutch Diagnosis........................................................................................................... 5303
Individual Inspection............................................................................................................... 5308
General Repair Procedure............................................................................................................ 5309
Leak Check.......................................................................................................................... 5312
Compressor Assembly..................................................................................................................... 5317
Compressor Assembly and Associated Parts............................................................................................ 5317
Removal............................................................................................................................. 5317
Installation........................................................................................................................ 5318
New Compressor Installation......................................................................................................... 5318
Condenser Assembly...................................................................................................................... 5319
Condenser Assembly and Associated Parts............................................................................................. 5319
Removal............................................................................................................................. 5319
Installation........................................................................................................................ 5319
Condenser Fan Motor..................................................................................................................... 5320
Condenser Fan Motor and Associated Parts............................................................................................ 5320
Removal............................................................................................................................. 5321
Installation........................................................................................................................ 5321
Receiver / Drier........................................................................................................................ 5321
Receiver / Drier and Associated Parts............................................................................................... 5321
Removal............................................................................................................................. 5321
Installation........................................................................................................................ 5321
Pressure Switch......................................................................................................................... 5322
Pressure Switch and Associated Parts................................................................................................ 5322
Removal............................................................................................................................. 5322
Installation........................................................................................................................ 5322
Evaporator Assembly..................................................................................................................... 5323
Evaporator Assembly and Associated Parts............................................................................................ 5323
Removal............................................................................................................................. 5323
Installation........................................................................................................................ 5324
Electronic Thermostat, Evaporator Core and/or Expansion Valve........................................................................... 5324
Disassembled View................................................................................................................... 5324
Removal............................................................................................................................. 5325
Installation........................................................................................................................ 5325
Refrigerant Line........................................................................................................................ 5326
Refrigerant Line and Associated Parts............................................................................................... 5326
Removal............................................................................................................................. 5327
Installation........................................................................................................................ 5327
Main Data And Specifications........................................................................................................ 5328
Compressor.............................................................................................................................. 5331
Service Precaution.................................................................................................................. 5331
General Description................................................................................................................. 5331
Diagnosis........................................................................................................................... 5332
Magnetic Clutch Assembly (DKV-14D Type)................................................................................................. 5333
Parts Location View................................................................................................................. 5333
Removal............................................................................................................................. 5333
Inspection and Repair............................................................................................................... 5335
Installation........................................................................................................................ 5335
Compressor Oil.......................................................................................................................... 5337
Oil Specification................................................................................................................... 5337
Handling of Oil..................................................................................................................... 5337
Compressor Oil Check................................................................................................................ 5337
Checking and Adjusting Oil Quantity for Used Compressor............................................................................. 5337
Checking and Adjusting for Compressor Replacement................................................................................... 5338
Contamination of Compressor Oil..................................................................................................... 5338
Oil Return Operation................................................................................................................ 5338
Replacement of Component Parts...................................................................................................... 5338
Main Data and Specifications............................................................................................................ 5339
Special Tools........................................................................................................................... 5341
Sec.2 STEERING................................................................................................................................ 5342
2A POWER ASSISTED SYSTEM.................................................................................................................. 5342
Service Precaution...................................................................................................................... 5343
General Description..................................................................................................................... 5343
Diagnosis............................................................................................................................... 5346
Power Steering System Test.............................................................................................................. 5352
Maintenance............................................................................................................................. 5352
Fluid Level............................................................................................................................. 5353
Bleeding The Power Steering System...................................................................................................... 5353
Bleeding Procedure...................................................................................................................... 5353
Flushing The Power Steering System...................................................................................................... 5353
Steering Wheel Free Play Adjustment..................................................................................................... 5353
Front End Alignment Inspection and Adjustment........................................................................................... 5354
Main Data and Specifications............................................................................................................ 5359
Special Tools........................................................................................................................... 5360
Power Steering Gear..................................................................................................................... 5361
Power Steering Gear and Associated Parts............................................................................................ 5361
Removal............................................................................................................................. 5361
Installation........................................................................................................................ 5362
Steering Gear Disassembled View..................................................................................................... 5363
Disassembly......................................................................................................................... 5363
Inspection and Repair............................................................................................................... 5365
Reassembly.......................................................................................................................... 5366
Main Data and Specifications........................................................................................................ 5368
Special Tools....................................................................................................................... 5369
Power Steering Pump..................................................................................................................... 5370
Power Steering Pump and Associated Parts............................................................................................ 5370
Removal............................................................................................................................. 5370
Installation........................................................................................................................ 5371
Power Steering Pump Disassembled View............................................................................................... 5372
Disassembly......................................................................................................................... 5372
Inspection and Repair............................................................................................................... 5373
Reassembly.......................................................................................................................... 5374
Main Data and Specifications........................................................................................................ 5375
Center Track Rod Assembly............................................................................................................... 5376
Center Track Rod Assembly and Associated Parts...................................................................................... 5376
Removal............................................................................................................................. 5376
Inspection and Repair............................................................................................................... 5377
Installation........................................................................................................................ 5377
Outer Track Rod Assembly................................................................................................................ 5378
Outer Track Rod Assembly and Associated Parts....................................................................................... 5378
Removal............................................................................................................................. 5378
Inspection and Repair............................................................................................................... 5380
Installation........................................................................................................................ 5380
Relay Lever............................................................................................................................. 5381
Relay Lever and Associated Parts.................................................................................................... 5381
Removal............................................................................................................................. 5381
Installation........................................................................................................................ 5382
Steering Linkage and Associated Parts................................................................................................... 5383
Main Data and Specifications........................................................................................................ 5383
Special Tools....................................................................................................................... 5384
Supplemental Restraint System Steering Wheel & Column................................................................................... 5385
Service Precaution.................................................................................................................. 5385
SRS Connectors (3 pin).............................................................................................................. 5385
SRS Connectors (2 pin).............................................................................................................. 5385
Inflator Module......................................................................................................................... 5387
Inflator Module and Associated Parts................................................................................................ 5387
Removal............................................................................................................................. 5387
Inspection and Repair............................................................................................................... 5388
Installation........................................................................................................................ 5388
Steering Wheel.......................................................................................................................... 5389
Steering Wheel and Associated Parts................................................................................................. 5389
Removal............................................................................................................................. 5389
Installation........................................................................................................................ 5391
Combination Switch...................................................................................................................... 5392
Combination Switch and Associated Parts............................................................................................. 5392
Removal............................................................................................................................. 5392
Installation........................................................................................................................ 5394
Lock Cylinder........................................................................................................................... 5396
Lock Cylinder and Associated Parts.................................................................................................. 5396
Removal............................................................................................................................. 5396
Installation........................................................................................................................ 5398
System Inspection................................................................................................................... 5399
Steering Column......................................................................................................................... 5400
Steering Column and Associated Parts................................................................................................ 5400
Removal............................................................................................................................. 5400
Inspection.......................................................................................................................... 5402
Installation........................................................................................................................ 5404
System Inspection................................................................................................................... 5405
Supplemental Restraint System Steering Wheel & Column and Associated Parts.............................................................. 5406
Main Data and Specifications........................................................................................................ 5406
Special Tools....................................................................................................................... 5407
Sec.3 SUSPENSION.............................................................................................................................. 5408
3C FRONT SUSPENSION....................................................................................................................... 5408
Service Precaution...................................................................................................................... 5408
General Description..................................................................................................................... 5409
General Diagnosis....................................................................................................................... 5410
Shock Absorber.......................................................................................................................... 5413
Shock Absorber and Associated Parts................................................................................................. 5413
Removal............................................................................................................................. 5413
Inspection and Repair............................................................................................................... 5414
Installation........................................................................................................................ 5414
Stabilizer Bar.......................................................................................................................... 5415
Stabilizer Bar and Associated Parts................................................................................................. 5415
Removal............................................................................................................................. 5415
Inspection and Repair............................................................................................................... 5415
Installation........................................................................................................................ 5415
Torsion Bar............................................................................................................................. 5416
Torsion Bar and Associated Parts.................................................................................................... 5416
Removal............................................................................................................................. 5416
Inspection and Repair............................................................................................................... 5417
Installation........................................................................................................................ 5417
Special Tools........................................................................................................................... 5434
3D REAR SUSPENSION........................................................................................................................ 5435
Service Precaution...................................................................................................................... 5435
General Description..................................................................................................................... 5436
Coil Spring............................................................................................................................. 5437
Coil Spring and Associated Parts.................................................................................................... 5437
Removal............................................................................................................................. 5437
Inspection and Repair............................................................................................................... 5438
Installation........................................................................................................................ 5438
Shock Absorber.......................................................................................................................... 5439
Shock Absorber and Associated Parts................................................................................................. 5439
Removal............................................................................................................................. 5439
Inspection and Repair............................................................................................................... 5439
Installation........................................................................................................................ 5440
Trailing Link........................................................................................................................... 5441
Trailing Link and Associated Parts.................................................................................................. 5441
Removal............................................................................................................................. 5441
Inspection and Repair............................................................................................................... 5441
Installation........................................................................................................................ 5442
Center Link............................................................................................................................. 5443
Center Link and Associated Parts.................................................................................................... 5443
Removal............................................................................................................................. 5443
Inspection and Repair............................................................................................................... 5443
Installation........................................................................................................................ 5444
Lateral Rod............................................................................................................................. 5445
Lateral Rod and Associated Parts.................................................................................................... 5445
Removal............................................................................................................................. 5445
Inspection and Repair............................................................................................................... 5445
Installation........................................................................................................................ 5446
Stabilizer Bar.......................................................................................................................... 5447
Stabilizer Bar and Associated Parts................................................................................................. 5447
Removal............................................................................................................................. 5447
Inspection and Repair............................................................................................................... 5447
Installation........................................................................................................................ 5448
Main Data and Specifications............................................................................................................ 5449
Special Tools........................................................................................................................... 5451
3E WHEEL AND TIRE SYSTEM.................................................................................................................. 5452
Service Precaution...................................................................................................................... 5452
General Description..................................................................................................................... 5453
Diagnosis............................................................................................................................... 5454
Wheel................................................................................................................................... 5460
Wheel and Associated Parts.......................................................................................................... 5460
Removal............................................................................................................................. 5460
Installation........................................................................................................................ 5460
Tire.................................................................................................................................... 5461
Tire Replacement.................................................................................................................... 5461
Temporary Spare Tire................................................................................................................ 5461
General Balance Procedure........................................................................................................... 5461
Balancing Wheel and Tire............................................................................................................ 5462
Main Data and Specifications............................................................................................................ 5463
Sec.4 DRIVELINE/AXLE.......................................................................................................................... 5464
4A1 DIFFERENTIAL (FRONT)................................................................................................................... 5464
Service Precaution...................................................................................................................... 5464
Front Drive Axle........................................................................................................................ 5465
Diagnosis........................................................................................................................... 5465
Pinion Shaft Oil Seal................................................................................................................... 5466
Pinion Shaft Oil Seal and Associated Parts.......................................................................................... 5466
Removal............................................................................................................................. 5466
Inspection and Repair............................................................................................................... 5467
Installation........................................................................................................................ 5467
Front Drive Axle Assembly............................................................................................................... 5468
Front Drive Axle Assembly and Associated Parts...................................................................................... 5468
Removal............................................................................................................................. 5468
Installation........................................................................................................................ 5469
Differential Assembly................................................................................................................... 5471
Disassembled View................................................................................................................... 5471
Disassembly......................................................................................................................... 5472
Reassembly.......................................................................................................................... 5474
Differential Cage Assembly.............................................................................................................. 5483
Disassembled View................................................................................................................... 5483
Disassembly......................................................................................................................... 5483
Inspection and Repair............................................................................................................... 5484
Reassembly.......................................................................................................................... 5485
Main Data and Specifications............................................................................................................ 5487
Special Tools........................................................................................................................... 5489
4A2 DIFFERENTIAL (REAR).................................................................................................................... 5491
Service Precaution...................................................................................................................... 5491
General Description..................................................................................................................... 5492
Diagnosis............................................................................................................................... 5493
Axle Housing............................................................................................................................ 5494
Axle Housing and Associated Parts................................................................................................... 5494
Removal............................................................................................................................. 5494
Oil Seal Replacement................................................................................................................ 5495
Installation........................................................................................................................ 5495
Pinion Oil Seal......................................................................................................................... 5496
Pinion Oil Seal and Associated Parts................................................................................................ 5496
Removal............................................................................................................................. 5496
Inspection and Repair............................................................................................................... 5497
Installation........................................................................................................................ 5497
Differential Assembly................................................................................................................... 5498
Differential Assembly and Associated Parts.......................................................................................... 5498
Removal............................................................................................................................. 5498
Installation........................................................................................................................ 5499
Disassembled View................................................................................................................... 5500
Disassembly......................................................................................................................... 5501
Reassembly.......................................................................................................................... 5503
Limited Slip Differential............................................................................................................... 5511
Disassembled View................................................................................................................... 5511
Disassembly......................................................................................................................... 5512
Inspection and Repair............................................................................................................... 5512
Reassembly.......................................................................................................................... 5514
Main Data and Specifications............................................................................................................ 5517
Special Tools........................................................................................................................... 5518
4B2 DRIVELINE CONTROL SYSTEM (TOD)......................................................................................................... 5520
Service Precaution...................................................................................................................... 5520
General Description..................................................................................................................... 5521
System Components....................................................................................................................... 5523
Parts Location...................................................................................................................... 5523
Functions of Indicator Lamp............................................................................................................. 5527
Diagnosis............................................................................................................................... 5531
Basic Diagnostic Flow Chart............................................................................................................. 5534
Parts Location.......................................................................................................................... 5535
Circuit Diagram......................................................................................................................... 5536
Connector List.......................................................................................................................... 5539
Checking Failed Pin..................................................................................................................... 5540
Checking Failed TOD Control Unit Pin.................................................................................................... 5543
Tech 2 Scan Tool.................................................................................................................... 5544
Diagnostic Trouble Codes................................................................................................................ 5547
Diagnosis from Trouble Codes............................................................................................................ 5548
Trouble Diagnosis Depending on The Status of TOD Indicator.............................................................................. 5565
Diagnosis from Symptom.................................................................................................................. 5584
4C DRIVE SHAFT SYSTEM..................................................................................................................... 5592
Service Precaution...................................................................................................................... 5592
General Description..................................................................................................................... 5592
Diagnosis............................................................................................................................... 5593
Front Hub and Disc...................................................................................................................... 5594
Disassembled View................................................................................................................... 5594
Disassembly......................................................................................................................... 5594
Inspection and Repair............................................................................................................... 5595
Reassembly.......................................................................................................................... 5596
Main Data and Specifications........................................................................................................ 5599
Special Tools....................................................................................................................... 5600
Front Drive Shaft Joint................................................................................................................. 5601
Front Drive Shaft Joints Replacement................................................................................................ 5601
Front Axle Drive Shaft.................................................................................................................. 5602
Front Axle Drive Shaft and Associated Parts......................................................................................... 5602
Disassembly......................................................................................................................... 5603
Inspection and Repair............................................................................................................... 5604
Bushing Replacement................................................................................................................. 5604
Reassembly.......................................................................................................................... 5605
Front Propeller Shaft................................................................................................................... 5607
General Description................................................................................................................. 5607
Front Propeller Shaft and Associated Parts.......................................................................................... 5607
Removal............................................................................................................................. 5608
Installation........................................................................................................................ 5608
Inspection and Repair............................................................................................................... 5609
Main Data and Specifications........................................................................................................ 5611
Rear Propeller Shaft.................................................................................................................... 5612
General Description................................................................................................................. 5612
Rear Propeller Shaft and Associated Parts........................................................................................... 5612
Removal............................................................................................................................. 5613
Installation........................................................................................................................ 5613
Disassembly......................................................................................................................... 5614
Universal Joint Disassembly......................................................................................................... 5615
Inspection and Repair............................................................................................................... 5616
Universal Joint Reassembly.......................................................................................................... 5617
Reassembly.......................................................................................................................... 5618
Main Data and Specifications........................................................................................................ 5619
4D2 TRANSFER CASE (TOD).................................................................................................................... 5620
Service Precaution...................................................................................................................... 5620
Transfer Case Assembly.................................................................................................................. 5621
Removal............................................................................................................................. 5622
Installation........................................................................................................................ 5622
Transfer Rear Oil Seal.................................................................................................................. 5624
Transfer Rear Oil Seal and Associated Parts......................................................................................... 5624
Removal............................................................................................................................. 5624
Installation........................................................................................................................ 5624
TOD ECU................................................................................................................................. 5626
Removal............................................................................................................................. 5626
Installation........................................................................................................................ 5626
Unit Repair............................................................................................................................. 5627
Inspection.......................................................................................................................... 5627
Transfer Case........................................................................................................................... 5628
Disassembled View................................................................................................................... 5628
Disassembly......................................................................................................................... 5628
Reassembly.......................................................................................................................... 5629
Transfer Cover Assembly................................................................................................................. 5631
Disassembled View................................................................................................................... 5631
Disassembly......................................................................................................................... 5631
Reassembly.......................................................................................................................... 5633
Transfer Case Assembly Clutch Pack and Clutch Cam....................................................................................... 5635
Disassembled View................................................................................................................... 5635
Disassembly......................................................................................................................... 5635
Sprocket and Mechanical Lock............................................................................................................ 5637
Disassembled View................................................................................................................... 5637
Disassembly......................................................................................................................... 5637
Output Shafts and Shift Control Shaft................................................................................................... 5639
Disassembled View................................................................................................................... 5639
Disassembly......................................................................................................................... 5640
Transfer Case........................................................................................................................... 5642
Disassembled View................................................................................................................... 5642
Disassembly......................................................................................................................... 5643
Inspection and Repair............................................................................................................... 5645
Transfer Case........................................................................................................................... 5649
Disassembled View................................................................................................................... 5649
Reassembly.......................................................................................................................... 5649
Output Shafts and Shift Control Shaft................................................................................................... 5653
Disassembled View................................................................................................................... 5653
Reassembly.......................................................................................................................... 5653
Sprocket and Mechanical Lock............................................................................................................ 5656
Disassembled View................................................................................................................... 5656
Reassembly.......................................................................................................................... 5656
Clutch Pack and Clutch Cam.............................................................................................................. 5658
Disassembled View................................................................................................................... 5658
Reassembly.......................................................................................................................... 5658
Main Data and Specifications............................................................................................................ 5660
Special Tools........................................................................................................................... 5662
Sec.5 BRAKES.................................................................................................................................. 5663
5A BRAKE CONTROL SYSTEM................................................................................................................... 5663
Service Precaution...................................................................................................................... 5664
General Description..................................................................................................................... 5665
System Components................................................................................................................... 5666
Electronic Hydraulic Control Unit (EHCU)............................................................................................ 5666
ABS Warning Light................................................................................................................... 5666
Wheel Speed Sensor.................................................................................................................. 5666
G-Sensor............................................................................................................................ 5666
Normal and Anti-lock Braking........................................................................................................ 5666
Brake Pedal Travel.................................................................................................................. 5666
Acronyms and Abbreviations.......................................................................................................... 5666
General Diagnosis....................................................................................................................... 5667
General Information................................................................................................................. 5667
ABS Service Precautions............................................................................................................. 5667
General Service Precautions......................................................................................................... 5667
Note on Intermittents............................................................................................................... 5667
Test Driving ABS Complaint Vehicles................................................................................................. 5668
"ABS" Warning Light................................................................................................................. 5668
Normal Operation.................................................................................................................... 5668
Basic Diagnostic Flow Chart......................................................................................................... 5668
Basic Inspection Procedure.......................................................................................................... 5669
Tech 2 Scan Tool.................................................................................................................... 5670
Getting Started..................................................................................................................... 5671
Operating Procedure................................................................................................................. 5671
Data List............................................................................................................................... 5673
EHCU Connector Pin-out Checks........................................................................................................... 5674
Circuit Diagram..................................................................................................................... 5675
Connector List...................................................................................................................... 5677
Part Location....................................................................................................................... 5679
Symptom Diagnosis....................................................................................................................... 5680
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate...................................................................... 5681
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................ 5682
Chart A-2 Uneven Braking Occurs While ABS Works..................................................................................... 5682
Chart A-3, TA-3 The Wheels Are Locked............................................................................................... 5683
Chart A-4 Brake Pedal Feed Is Abnormal.............................................................................................. 5684
Chart A-5,TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................. 5685
Diagnostic Trouble Codes................................................................................................................ 5686
Diagnosis By "ABS" Warning Light Illumination Pattern................................................................................... 5687
Diagnostic Trouble Codes (DTCs)..................................................................................................... 5688
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................ 5691
Chart B-2 EHCU Abnormality (DTC 14)................................................................................................. 5691
Chart B-3 Power Voltage Drop (DTC 15)............................................................................................... 5692
Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)........................................................................... 5692
Chart B-5 G-Sensor Circuit (DTC 21)................................................................................................. 5693
Chart B-6 Abnormal Transmission Input (DTC 23)...................................................................................... 5694
Chart B-7 Transfer Monitor (DTC 24)................................................................................................. 5694
Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32).......................................................................... 5695
Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35).......................................................................... 5695
Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41)......................................................................... 5695
Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42).............................................................................. 5696
Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43)......................................................................... 5696
Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44).............................................................................. 5696
Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45)....................................................................... 5697
Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)............................................................................ 5697
Chart B-16 FL Speed Sensor Disconnection (DTC 51)................................................................................... 5697
Chart B-17 FR Speed Sensor Disconnection (DTC 52)................................................................................... 5698
Chart B-18 RL Speed Sensor Disconnection (DTC 53)................................................................................... 5698
Chart B-19 RR Speed Sensor Disconnection (DTC 54)................................................................................... 5699
Chart B-20 FL Speed Sensor Short Circuit (DTC 61)................................................................................... 5700
Chart B-21 FR Speed Sensor Short Circuit (DTC 62)................................................................................... 5701
Chart B-22 RL Speed Sensor Short Circuit (DTC 63)................................................................................... 5702
Chart B-23 RR Speed Sensor Short Circuit (DTC 64)................................................................................... 5703
Chart B-24 Sensor Signal Input Abnormality (DTC 65)................................................................................. 5704
Sensor Signal Abnormality Criteria using TECH 2..................................................................................... 5704
Unit Inspection Procedure............................................................................................................... 5705
Chart C-1-1 FL Sensor Output Inspection Procedure................................................................................... 5705
Chart C-1-2 FR Sensor Output Inspection Procedure................................................................................... 5706
Chart C-1-3 RL Sensor Output Inspection Procedure................................................................................... 5706
Chart C-1-4 RR Sensor Output Inspection Procedure................................................................................... 5707
Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2).......................................................................... 5707
Chart C-2 Transmission Input Inspection Procedure................................................................................... 5708
Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2)..................................................................... 5708
Special Tools........................................................................................................................... 5709
5B ANTI-LOCK BRAKE SYSTEM................................................................................................................. 5710
Service Precaution...................................................................................................................... 5710
Electronic Hydraulic Control Unit....................................................................................................... 5711
Electronic Hydraulic Control Unit and Associated Parts.............................................................................. 5711
Removal............................................................................................................................. 5711
Installation........................................................................................................................ 5711
G-Sensor................................................................................................................................ 5712
Removal............................................................................................................................. 5712
Inspection and Repair............................................................................................................... 5712
Installation........................................................................................................................ 5712
Front Wheel Speed Sensor................................................................................................................ 5713
Front Wheel Speed Sensor and Associated Parts....................................................................................... 5713
Removal............................................................................................................................. 5713
Inspection and Repair............................................................................................................... 5714
Installation........................................................................................................................ 5714
Rear Wheel Speed Sensor................................................................................................................. 5715
Rear Wheel Speed Sensor and Associated Parts........................................................................................ 5715
Removal............................................................................................................................. 5715
Inspection and Repair............................................................................................................... 5715
Installation........................................................................................................................ 5715
5C POWER-ASSISTED BRAKE SYSTEM............................................................................................................ 5716
Service Precaution...................................................................................................................... 5717
General Description..................................................................................................................... 5717
Diagnosis............................................................................................................................... 5720
General Diagnosis....................................................................................................................... 5721
Hydraulic Brakes........................................................................................................................ 5724
Filling Master Cylinder Reservoir................................................................................................... 5724
Deterioration of Brake Fluid........................................................................................................ 5724
Leakage of Brake Fluid.............................................................................................................. 5724
Bleeding Brake Hydraulic System..................................................................................................... 5724
Flushing Brake Hydraulic System..................................................................................................... 5725
Brake Pipes and Hoses............................................................................................................... 5725
Brake Hose Inspection............................................................................................................... 5725
Front / Rear Caliper Brake Hose......................................................................................................... 5726
Front / Rear Caliper Brake Hose and Associated Parts................................................................................ 5726
Removal............................................................................................................................. 5726
Installation........................................................................................................................ 5726
Rear Axle Brake Hose.................................................................................................................... 5727
Rear Axle Brake Hose and Associated Parts........................................................................................... 5727
Removal............................................................................................................................. 5727
Installation........................................................................................................................ 5727
Brake Pipe.............................................................................................................................. 5728
Removal............................................................................................................................. 5728
Installation........................................................................................................................ 5728
P & B (Proportioning and Bypass) Valve.................................................................................................. 5729
P & B (Proportioning and Bypass) Valve Sectional View............................................................................... 5729
Removal............................................................................................................................. 5729
Installation........................................................................................................................ 5729
Main Data and Specifications........................................................................................................ 5730
Brake Pedal............................................................................................................................. 5731
Checking Pedal Height............................................................................................................... 5731
Checking Pedal Travel............................................................................................................... 5731
Brake Pedal and Associated Parts.................................................................................................... 5732
Removal............................................................................................................................. 5732
Installation........................................................................................................................ 5732
Stoplight Switch........................................................................................................................ 5733
Removal............................................................................................................................. 5733
Installation........................................................................................................................ 5733
Main Data and Specifications........................................................................................................ 5734
Fluid Reservoir Tank.................................................................................................................... 5735
Fluid Reservoir Tank and Associated Parts........................................................................................... 5735
Removal............................................................................................................................. 5735
Installation........................................................................................................................ 5735
Master Cylinder Assembly................................................................................................................ 5736
Master Cylinder Assembly and Associated Parts....................................................................................... 5736
Removal............................................................................................................................. 5736
Inspection and Repair............................................................................................................... 5736
Installation........................................................................................................................ 5737
Main Data and Specifications........................................................................................................ 5738
Special Tools....................................................................................................................... 5739
Vacuum Booster Assembly................................................................................................................. 5740
Vacuum Booster Assembly and Associated Parts........................................................................................ 5740
Removal............................................................................................................................. 5740
Inspection and Repair............................................................................................................... 5740
Installation........................................................................................................................ 5741
Exterior Components..................................................................................................................... 5743
Exterior Components and Associated Parts............................................................................................ 5743
Removal............................................................................................................................. 5743
Inspection and Repair............................................................................................................... 5744
Installation........................................................................................................................ 5744
Vacuum Booster Overhaul................................................................................................................. 5744
Vacuum Booster...................................................................................................................... 5744
Main Data and Specifications........................................................................................................ 5745
Special Tools....................................................................................................................... 5746
Front Disc Brake Pads................................................................................................................... 5747
Front Disc Brake Pads Inspection.................................................................................................... 5747
Front Disc Brake Pads and Associated Parts.......................................................................................... 5747
Removal............................................................................................................................. 5748
Installation........................................................................................................................ 5748
Front Disc Brake Rotor.................................................................................................................. 5750
Inspection.......................................................................................................................... 5750
Replacing Brake Rotors.............................................................................................................. 5750
Front Disc Brake Caliper Assembly....................................................................................................... 5752
Front Disc Brake Caliper Assembly and Associated Parts.............................................................................. 5752
Removal............................................................................................................................. 5752
Installation........................................................................................................................ 5753
Front Disc Brake Caliper................................................................................................................ 5755
Front Disc Brake Caliper Disassembled View.......................................................................................... 5755
Disassembly......................................................................................................................... 5755
Inspection and Repair............................................................................................................... 5756
Reassembly.......................................................................................................................... 5756
Main Data and Specifications........................................................................................................ 5758
Rear Disc Brake Pads.................................................................................................................... 5759
Brake Pads Inspection............................................................................................................... 5759
Brake Pads and Associated Parts..................................................................................................... 5759
Removal............................................................................................................................. 5760
Installation........................................................................................................................ 5760
Rear Disc Brake Rotor................................................................................................................... 5762
Inspection.......................................................................................................................... 5762
Replacing Brake Rotors.............................................................................................................. 5762
Refinishing Brake Rotors............................................................................................................ 5762
Rear Drum (In Disc) Inside Diameter Check........................................................................................... 5763
Rear Disc Brake Caliper Assembly........................................................................................................ 5764
Rear Disc Brake Caliper Assembly and Associated Parts............................................................................... 5764
Removal............................................................................................................................. 5764
Installation........................................................................................................................ 5765
Rear Disc Brake Caliper................................................................................................................. 5767
Rear Disc Brake Caliper Disassembled View........................................................................................... 5767
Disassembly......................................................................................................................... 5767
Inspection and Repair............................................................................................................... 5768
Reassembly.......................................................................................................................... 5768
Main Data and Specifications........................................................................................................ 5770
5D PARKING BRAKE SYSTEM................................................................................................................... 5771
Service Precaution...................................................................................................................... 5771
General Description..................................................................................................................... 5771
Operation............................................................................................................................... 5772
Parking Brake Lever and Front Cable..................................................................................................... 5773
Parking Brake Lever, Front Cable and Associated Parts............................................................................... 5773
Removal............................................................................................................................. 5773
Installation........................................................................................................................ 5774
Parking Brake Rear Cable................................................................................................................ 5775
Parking Brake Rear Cable and Associated Parts....................................................................................... 5775
Removal............................................................................................................................. 5775
Installation........................................................................................................................ 5776
Inspection and Repair............................................................................................................... 5777
Parking Brake Adjustment............................................................................................................ 5777
Main Data and Specifications............................................................................................................ 5778
Sec.6 ENGINE.................................................................................................................................. 5779
6A ENGINE MECHANICAL...................................................................................................................... 5779
Service Precaution...................................................................................................................... 5780
General Description..................................................................................................................... 5781
Engine Diagnosis........................................................................................................................ 5782
Cylinder Head Cover LH.................................................................................................................. 5796
Removal............................................................................................................................. 5796
Installation........................................................................................................................ 5797
Cylinder Head Cover RH.................................................................................................................. 5799
Removal............................................................................................................................. 5799
Installation........................................................................................................................ 5800
Common Chamber.......................................................................................................................... 5802
Removal............................................................................................................................. 5802
Installation........................................................................................................................ 5802
Exhaust Manifold LH..................................................................................................................... 5804
Removal............................................................................................................................. 5804
Installation........................................................................................................................ 5804
Exhaust Manifold RH..................................................................................................................... 5806
Removal............................................................................................................................. 5806
Installation........................................................................................................................ 5807
Crankshaft Pulley....................................................................................................................... 5808
Removal............................................................................................................................. 5808
Installation........................................................................................................................ 5808
Timing Belt............................................................................................................................. 5809
Removal............................................................................................................................. 5809
Installation........................................................................................................................ 5810
Camshaft................................................................................................................................ 5813
Removal............................................................................................................................. 5813
Installation........................................................................................................................ 5813
Cylinder Head........................................................................................................................... 5816
Removal............................................................................................................................. 5816
Installation........................................................................................................................ 5816
Valve Stem Oil Controller , Valve Spring and Valve Guide................................................................................ 5818
Removal............................................................................................................................. 5818
Installation........................................................................................................................ 5818
Piston, Piston Ring and Connecting Rod.................................................................................................. 5819
Removal............................................................................................................................. 5819
Installation........................................................................................................................ 5820
Crankshaft and Main Bearings............................................................................................................ 5821
Removal............................................................................................................................. 5821
Installation........................................................................................................................ 5822
Rear Oil Seal........................................................................................................................... 5826
Removal............................................................................................................................. 5826
Installation........................................................................................................................ 5826
Engine Assembly......................................................................................................................... 5827
Removal............................................................................................................................. 5827
Installation........................................................................................................................ 5827
Cylinder Head........................................................................................................................... 5830
Cylinder Head and Associated Parts.................................................................................................. 5830
Disassembly......................................................................................................................... 5830
Clean............................................................................................................................... 5831
Inspection and Repair............................................................................................................... 5831
Reassembly.......................................................................................................................... 5831
Valve Spring, Oil Controller, Valve, Valve Guide........................................................................................ 5834
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts............................................................... 5834
Disassembly......................................................................................................................... 5834
Inspection and Repair............................................................................................................... 5835
Reassembly.......................................................................................................................... 5838
Valve Clearance Adjustments......................................................................................................... 5839
Camshaft................................................................................................................................ 5841
Camshaft and Associated Parts....................................................................................................... 5841
Disassembly......................................................................................................................... 5841
Inspection and Repair............................................................................................................... 5842
Reassembly.......................................................................................................................... 5844
Crankshaft.............................................................................................................................. 5847
Crankshaft and Associated Parts..................................................................................................... 5847
Disassembly......................................................................................................................... 5847
Inspection and Repair............................................................................................................... 5848
Inspection and Repair............................................................................................................... 5849
Reassembly.......................................................................................................................... 5851
Piston and Connecting Rod............................................................................................................... 5855
Piston, Connecting Rod and Associate Parts.......................................................................................... 5855
Disassembly......................................................................................................................... 5855
Inspection and Repair............................................................................................................... 5856
Reassembly.......................................................................................................................... 5860
Cylinder Block.......................................................................................................................... 5863
Cylinder Block and Associated Parts................................................................................................. 5863
Disassembly......................................................................................................................... 5863
Inspection and Repair............................................................................................................... 5864
Reassembly.......................................................................................................................... 5865
Main Data and Specification............................................................................................................. 5868
Special Tool............................................................................................................................ 5874
6B ENGINE COOLING......................................................................................................................... 5876
Service Precaution...................................................................................................................... 5876
General Description..................................................................................................................... 5877
Diagnosis............................................................................................................................... 5880
Draining and Refilling Cooling System................................................................................................... 5881
Engine coolant change................................................................................................................... 5881
Water Pump.............................................................................................................................. 5882
Water Pump and Associated Parts..................................................................................................... 5882
Removal............................................................................................................................. 5882
Inspection.......................................................................................................................... 5882
Installation........................................................................................................................ 5882
Thermostat.............................................................................................................................. 5883
Thermostat and Associated Parts..................................................................................................... 5883
Removal............................................................................................................................. 5883
Inspection.......................................................................................................................... 5883
Installation........................................................................................................................ 5883
Radiator................................................................................................................................ 5884
Radiator and Associated Parts....................................................................................................... 5884
Removal............................................................................................................................. 5884
Inspection.......................................................................................................................... 5885
Installation........................................................................................................................ 5886
Drive Belt and Cooling Fan.............................................................................................................. 5887
Drive Belt and Associated Parts..................................................................................................... 5887
Inspection.......................................................................................................................... 5887
Installation........................................................................................................................ 5887
Main Data and Specifications............................................................................................................ 5888
Special Tool............................................................................................................................ 5889
6C ENGINE FUEL............................................................................................................................ 5890
Service Precaution...................................................................................................................... 5890
General Description..................................................................................................................... 5891
Fuel Metering........................................................................................................................... 5892
Fuel Filter............................................................................................................................. 5893
Fuel Filter and Associated Parts.................................................................................................... 5893
Removal............................................................................................................................. 5893
Inspection.......................................................................................................................... 5893
Installation........................................................................................................................ 5893
Inspection.......................................................................................................................... 5894
In-Tank Fuel Filter................................................................................................................. 5894
Fuel Pump Flow Test................................................................................................................. 5894
Fuel Pump............................................................................................................................... 5895
Fuel Pump and Associated Parts...................................................................................................... 5895
Removal............................................................................................................................. 5895
Installation........................................................................................................................ 5895
Fuel Pump Relay......................................................................................................................... 5896
General Description................................................................................................................. 5896
Fuel Tank............................................................................................................................... 5896
Fuel Tank and Associated Parts...................................................................................................... 5896
Removal............................................................................................................................. 5897
Installation........................................................................................................................ 5897
Fuel Tube / Quick-Connect Fittings...................................................................................................... 5897
Precautions......................................................................................................................... 5897
Cautions During Work................................................................................................................ 5897
Removal............................................................................................................................. 5897
Reuse of Quick-Connector............................................................................................................ 5899
Assembling Advice................................................................................................................... 5899
Fuel Gauge Unit......................................................................................................................... 5900
Fuel Gauge Unit and Associated Parts................................................................................................ 5900
Removal............................................................................................................................. 5900
Installation........................................................................................................................ 5900
Fuel Filler Cap......................................................................................................................... 5901
General Description................................................................................................................. 5901
Inspection.......................................................................................................................... 5901
Main Data and Specifications............................................................................................................ 5901
6D1 ENGINE ELECTRICAL...................................................................................................................... 5902
Battery................................................................................................................................. 5902
General Description..................................................................................................................... 5902
Diagnosis............................................................................................................................... 5902
Battery Charging.................................................................................................................... 5903
Jump Starting....................................................................................................................... 5903
Battery Removal..................................................................................................................... 5904
Battery Installation................................................................................................................ 5904
Main Data and Specifications............................................................................................................ 5905
6D2 IGNITION SYSTEM........................................................................................................................ 5906
Service Precaution...................................................................................................................... 5906
General Description..................................................................................................................... 5907
Diagnosis............................................................................................................................... 5910
Ignition Coil........................................................................................................................... 5910
Removal............................................................................................................................. 5910
Inspection and Repair............................................................................................................... 5910
Installation........................................................................................................................ 5910
Spark Plug.............................................................................................................................. 5911
Removal............................................................................................................................. 5911
Inspection and Repair............................................................................................................... 5911
Installation........................................................................................................................ 5911
Crankshaft Position Sensor.............................................................................................................. 5912
Removal............................................................................................................................. 5912
Installation........................................................................................................................ 5912
Main Data and Specifications............................................................................................................ 5913
6D3 STARTING AND CHARGING SYSTEM........................................................................................................... 5914
Service Precaution...................................................................................................................... 5914
Starting System......................................................................................................................... 5915
General Description..................................................................................................................... 5915
Diagnosis............................................................................................................................... 5917
Starter................................................................................................................................. 5918
Removal............................................................................................................................. 5918
Installation........................................................................................................................ 5918
Disassembled View................................................................................................................... 5919
Disassembly......................................................................................................................... 5920
Inspection and Repair............................................................................................................... 5922
Reassembly.......................................................................................................................... 5926
Main Data and Specifications........................................................................................................ 5928
Charging System......................................................................................................................... 5931
General Description..................................................................................................................... 5931
General On-Vehicle Inspection........................................................................................................... 5931
Generator............................................................................................................................... 5932
Removal............................................................................................................................. 5932
Inspection.......................................................................................................................... 5932
Installation........................................................................................................................ 5932
Disassembled View................................................................................................................... 5933
Disassembly......................................................................................................................... 5934
Inspection and Repair............................................................................................................... 5936
Reassembly.......................................................................................................................... 5938
Bench Test.......................................................................................................................... 5938
Main Data and Specifications............................................................................................................ 5939
6E 3.5L ENGINE DRIVEABILITY AND EMISSIONS................................................................................................. 5940
Specifications.......................................................................................................................... 5944
Tightening Specifications........................................................................................................... 5944
Diagrams and Schematics................................................................................................................. 5945
PCM Wiring Diagram (1 of 8)......................................................................................................... 5945
PCM Wiring Diagram (2 of 8)......................................................................................................... 5946
PCM Wiring Diagram (3 of 8)......................................................................................................... 5947
PCM Wiring Diagram (4 of 8)......................................................................................................... 5948
PCM Wiring Diagram (5 of 8)......................................................................................................... 5949
PCM Wiring Diagram (6 of 8)......................................................................................................... 5950
PCM Wiring Diagram (7 of 8)......................................................................................................... 5951
PCM Wiring Diagram (8 of 8)......................................................................................................... 5952
PCM Pinouts............................................................................................................................. 5953
PCM Pinout Table, 32-Way Red Connector-Row "A"...................................................................................... 5953
PCM Pinout Table, 32-Way Red Connector-Row "B"...................................................................................... 5955
PCM Pinout Table, 32-Way White Connector-Row "C".................................................................................... 5956
PCM Pinout Table, 32-Way White Connector-Row "D".................................................................................... 5957
PCM Pinout Table, 32-Way Blue Connector-Row "E"..................................................................................... 5959
PCM Pinout Table, 32-Way Blue Connector-Row "F"..................................................................................... 5960
Component Locators...................................................................................................................... 5961
Engine Component Locator............................................................................................................ 5961
Engine Component Locator Table...................................................................................................... 5961
Undercarriage Component Locator..................................................................................................... 5962
Undercarriage Component Locator Table............................................................................................... 5962
Fuse and Relay Panel (Underhood Electrical Center).................................................................................. 5963
Sensors and Miscellaneous Component Locators........................................................................................ 5964
Diagnosis............................................................................................................................... 5966
Strategy-Based Diagnostics.......................................................................................................... 5966
DTC Stored.......................................................................................................................... 5966
No DTC.............................................................................................................................. 5966
No Matching Symptom................................................................................................................. 5966
Intermittents....................................................................................................................... 5966
No Trouble Found.................................................................................................................... 5966
Verifying Vehicle Repair............................................................................................................ 5966
General Service Information............................................................................................................. 5966
OBD II Serviceablity Issues......................................................................................................... 5966
Emissions Control Information Label................................................................................................. 5967
Maintenance Schedule................................................................................................................ 5967
Visual / Physical Engine Compartment Inspection..................................................................................... 5967
Basic Knowledge of Tools Required................................................................................................... 5968
Serial Data Communications.............................................................................................................. 5968
Class II Serial Data Communications................................................................................................. 5968
On-Board Diagnostic (OBD) II............................................................................................................ 5968
On-Board Diagnostic Tests........................................................................................................... 5968
Comprehensive Component Monitor Diagnostic Operation................................................................................ 5968
System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations................................... 5969
Common OBD II Terms................................................................................................................. 5969
The Diagnostic Executive............................................................................................................ 5969
DTC Types........................................................................................................................... 5970
Decimal/Binary/Hexadecimal Conversions.............................................................................................. 5972
Verifying Vehicle Repair............................................................................................................ 5972
Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool......................................................................... 5972
Tech 2.............................................................................................................................. 5973
Tech 2 Features..................................................................................................................... 5973
Getting Started..................................................................................................................... 5974
Operating Procedure (For Example)................................................................................................... 5974
DTC Modes........................................................................................................................... 5975
DTC Information Mode................................................................................................................ 5976
Miscellaneous Test.................................................................................................................. 5976
Lamps Test.......................................................................................................................... 5977
Relays Test......................................................................................................................... 5978
EVAP Test........................................................................................................................... 5979
Idle Air Control (IAC) System Test.................................................................................................. 5980
Fuel System Test.................................................................................................................... 5982
EGR Control Test.................................................................................................................... 5983
Variable Intake Manifold Solenoid Test.............................................................................................. 5984
Injector Balance Test............................................................................................................... 5985
Plotting Snapshot Graph................................................................................................................. 5986
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)...................................................... 5987
Flow Chart for Snapshot Replay (Plotting Graph)..................................................................................... 5988
Primary System-Based Diagnostic......................................................................................................... 5989
Fuel Control Heated Oxygen Sensor................................................................................................... 5989
HO2S Heater......................................................................................................................... 5989
Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation..................................................................... 5989
Misfire Monitor Diagnostic Operation.................................................................................................... 5990
Misfire Counters.................................................................................................................... 5990
Fuel Trim System Monitor Diagnostic Operation........................................................................................... 5991
Fuel Trim Cell Diagnostic Weights................................................................................................... 5991
On-Board Diagnostic (OBD II) System Check............................................................................................... 5992
A/C Clutch Control Circuit Diagnosis.................................................................................................... 5995
Electronic Ignition System Diagnosis.................................................................................................... 6001
Visual Check of The Evaporative Emission Canister....................................................................................... 6001
Fuel Metering System Check.............................................................................................................. 6001
Idle Air Control (IAC) Valve............................................................................................................ 6001
Fuel System Pressure Test............................................................................................................... 6001
Fuel Injector Coil Test Procedure Fuel Injector Balance Test Procedure.................................................................. 6001
Knock Sensor Diagnosis.................................................................................................................. 6006
Powertrain Control Module (PCM) Diagnosis............................................................................................... 6006
Multiple PCM Information Sensor DTCS Set................................................................................................ 6006
Exhaust Gas Recirculation (EGR) Diagnosis............................................................................................... 6009
Engine Tech 2 Data Definitions and Ranges............................................................................................... 6009
Typical Scan Data Values................................................................................................................ 6012
No Malfunction Indicator Lamp (MIL)..................................................................................................... 6018
Malfunction Indicator Lamp (MIL) "ON" Steady............................................................................................ 6021
Engine Cranks But Will Not Run.......................................................................................................... 6023
Fuel System Electrical Test............................................................................................................. 6029
Fuel System Diagnosis................................................................................................................... 6032
Idle Air Control (IAC) System Check..................................................................................................... 6037
Knock Sensor (KS) System Check (Engine Knock, Poor Performance, or Poor Economy)........................................................ 6040
Exhaust Gas Recirculation (EGR) System Check............................................................................................ 6042
Manifold Absolute Pressure (MAP) Output Check........................................................................................... 6044
Evaporative (EVAP) Emissions Canister Purge Valve Check................................................................................. 6046
PCM Diagnostic Trouble Codes............................................................................................................ 6049
Diagnostic Trouble Code (DTC) P0101 MAF System Performance.............................................................................. 6053
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency.................................................................... 6056
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency................................................................... 6059
Diagnostic Trouble Code (DTC) P0106 MAP System Performance.............................................................................. 6062
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage...................................................................... 6065
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage..................................................................... 6068
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage...................................................................... 6071
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage..................................................................... 6074
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage...................................................................... 6077
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage..................................................................... 6080
Diagnostic Trouble Code (DTC) P0121 TP System Performance............................................................................... 6083
Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage....................................................................... 6086
Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage...................................................................... 6089
Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control...................................................... 6092
Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1............................................................ 6095
Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1........................................................... 6098
Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1.................................................................. 6101
Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1.................................................. 6105
Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1................................................................. 6108
Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2............................................................ 6111
Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2........................................................... 6114
Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2................................................... 6117
Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2................................................................. 6120
Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1............................................................ 6123
Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1........................................................... 6126
Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1.................................................................. 6129
Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1.................................................. 6133
Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Bank 2 Sensor 1................................................................. 6136
Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2............................................................ 6139
Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2........................................................... 6142
Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2.................................................. 6145
Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2................................................................. 6148
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1........................................................................ 6151
Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1........................................................................ 6155
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2........................................................................ 6159
Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2........................................................................ 6163
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit.......................................................................... 6167
Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit.......................................................................... 6170
Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit.......................................................................... 6173
Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit.......................................................................... 6176
Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit.......................................................................... 6179
Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit.......................................................................... 6182
Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected............................................................................. 6185
Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected........................................................................... 6189
Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected........................................................................... 6191
Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected........................................................................... 6193
Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected........................................................................... 6195
Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected........................................................................... 6197
Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected........................................................................... 6199
Diagnostic Trouble Code (DTC) P0325 KS Module Circuit................................................................................... 6201
Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit................................................................................... 6203
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit........................................................................ 6206
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency.................................................................... 6209
Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performance...................................................................... 6212
Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low.............................................................................. 6216
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit.......................................................................... 6220
Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit.......................................................................... 6223
Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit.......................................................................... 6226
Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit.......................................................................... 6229
Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit.......................................................................... 6232
Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit.......................................................................... 6235
Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient............................................................................... 6238
Diagnostic Trouble Code (DTC) P0402 EGR Pintle Position Error........................................................................... 6241
Diagnostic Trouble Code (DTC) P0404 EGR Pintle Open/Stuck............................................................................... 6243
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage..................................................................................... 6245
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage.................................................................................... 6248
Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1.................................................................... 6251
Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2.................................................................... 6254
Diagnostic Trouble Code (DTC) P0440 EVAP System......................................................................................... 6256
Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected..................................................................... 6260
Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Blocked.......................................................................... 6263
Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor Low Voltage............................................................... 6266
Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor High Voltage.............................................................. 6269
Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit豊ow Voltage................................................................ 6272
Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit蓬igh Voktage............................................................... 6274
Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input............................................................................... 6276
Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM..................................................................... 6279
Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM.................................................................... 6282
Diagnostic Trouble Code (DTC) P0562 System Voltage Low.................................................................................. 6285
Diagnostic Trouble Code (DTC) P0563 System Voltage High................................................................................. 6287
Diagnostic Trouble Code (DTC) P0601 PCM Memory.......................................................................................... 6289
Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage........................................................ 6290
Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage................................................................ 6292
Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage........................................................ 6294
Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage......................................................... 6297
Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage......................................................... 6299
Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage........................................................ 6301
Diagnostic Trouble Code (DTC) P1121 TP Sensor Circuit Intermittent High Voltage......................................................... 6304
Diagnostic Trouble Code (DTC) P1122 TP Sensor Circuit Intermittent Low Voltage.......................................................... 6306
Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1......................................................... 6308
Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1.......................................................... 6312
Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1......................................................... 6316
Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1.................................................. 6320
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration................................................................ 6324
Diagnostic Trouble Code (DTC) P1380 ABS Rough Road ABS System Fault..................................................................... 6327
Diagnostic Trouble Code (DTC) P1381 ABS Rough Road Class 2 Serial Link Error............................................................ 6329
Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed.................................................................................... 6330
Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge................................................................... 6333
Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM.................................................................................. 6336
Diagnostic Trouble Code (DTC) P1509 IAC System High RPM................................................................................. 6339
Diagnostic Trouble Code (DTC) P1618 Serial Peripheral Interface (SPI) PCM Interprocessor Communication Error............................ 6342
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset................................................................................ 6343
Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM)................................................................. 6344
Diagnostic Trouble Code (DTC) P1650 Quad Driver Module "A" Fault........................................................................ 6347
Symptom Diagnosis....................................................................................................................... 6350
Default Matrix Table.................................................................................................................... 6377
On-Vehicle ServiceCamshaft Position (CMP) Sensor........................................................................................ 6380
Crankshaft Position (CKP) Sensor........................................................................................................ 6380
Engine Coolant Temperature (ECT) Sensor................................................................................................. 6381
Heated Oxygen Sensor (HO2S)............................................................................................................. 6382
Intake Air Temperature (IAT) Sensor..................................................................................................... 6384
Knock Sensor (KS)....................................................................................................................... 6385
Mass Air Flow (MAF) Sensor.............................................................................................................. 6386
Manifold Absolute Pressure (MAP) Sensor................................................................................................. 6387
Malfunction Indicator Lamp (MIL)........................................................................................................ 6388
Powertrain Control Module (PCM)......................................................................................................... 6388
EEPROM.................................................................................................................................. 6389
Throttle Position (TP) Sensor........................................................................................................... 6389
Vehicle Speed Sensor (VSS).............................................................................................................. 6390
Air Cleaner/Air Filter.................................................................................................................. 6391
Idle Air Control (IAC) Valve............................................................................................................ 6392
Common Chamber.......................................................................................................................... 6393
Accelerator Cable Assembly.............................................................................................................. 6393
Accelerator Pedal Replacement........................................................................................................... 6396
Fuel Filter Cap......................................................................................................................... 6398
Fuel Filter............................................................................................................................. 6398
Fuel Gauge Unit......................................................................................................................... 6400
Fuel Injectors.......................................................................................................................... 6401
Fuel Pressure Regulator................................................................................................................. 6403
Fuel Metering System.................................................................................................................... 6405
Fuel Pump Assembly...................................................................................................................... 6405
Fuel Pump Relay......................................................................................................................... 6406
Fuel Rail Assembly...................................................................................................................... 6406
Fuel Tank............................................................................................................................... 6407
Throttle Body (TB)...................................................................................................................... 6409
Electronic Ignition System.............................................................................................................. 6411
Catalytic Converter..................................................................................................................... 6412
Air Conditioning Relay.................................................................................................................. 6412
EVAP Canister Hoses..................................................................................................................... 6413
EVAP Canister........................................................................................................................... 6413
EVAP Canister Vent Solenoid............................................................................................................. 6414
Fuel Tank Pressure Sensor............................................................................................................... 6415
EVAP Canister Purge Solenoid............................................................................................................ 6415
Fuel Tank Vent Valve.................................................................................................................... 6416
Linear Exhaust Gas Recirculation (EGR) Valve............................................................................................ 6416
Positive Crankcase Ventilation (PCV) Valve.............................................................................................. 6417
Wiring and Connectors................................................................................................................... 6418
PCM Connectors and Terminals............................................................................................................ 6418
Wire Harness Repair: Twisted Shielded Cable............................................................................................. 6418
Twisted Leads........................................................................................................................... 6419
Weather-Pack Connector.................................................................................................................. 6421
Com-Pack III............................................................................................................................ 6422
Metri-Pack.............................................................................................................................. 6422
General Description (PCM and Sensors)................................................................................................... 6423
Catalyst Monitor Heated Oxygen Sensors.................................................................................................. 6424
58X Reference PCM Input............................................................................................................. 6423
A/C Request Signal.................................................................................................................. 6423
Crankshaft Position (CKP) Sensor.................................................................................................... 6423
Camshaft Position (CMP) Sensor and Signal........................................................................................... 6423
Engine Coolant Temperature (ECT) Sensor............................................................................................. 6423
Electrically Erasable Programmable Read Only Memory (EEPROM)........................................................................ 6424
Fuel Control Heated Oxygen Sensors.................................................................................................. 6424
Intake Air Temperature (IAT) Sensor................................................................................................. 6425
Knock Sensor........................................................................................................................ 6425
Linear Exhaust Gas Recirculation (EGR) Control...................................................................................... 6426
Mass Air Flow (MAF) Sensor.......................................................................................................... 6426
Manifold Absolute Pressure (MAP) Sensor............................................................................................. 6426
Manifold Absolute Pressure (MAP) Sensor............................................................................................. 6426
Powertrain Control Module (PCM)..................................................................................................... 6427
PCM Function........................................................................................................................ 6427
PCM Components...................................................................................................................... 6427
PCM Voltage Description............................................................................................................. 6427
PCM Input/Outputs................................................................................................................... 6427
PCM Service Precautions............................................................................................................. 6428
Reprogramming The PCM............................................................................................................... 6428
Throttle Position (TP) Sensor....................................................................................................... 6428
Transmission Fluid Temperature (TFT) Sensor......................................................................................... 6428
Transmission Range Switch........................................................................................................... 6428
Vehicle Speed Sensor (VSS).......................................................................................................... 6429
Use of Circuit Testing Tools........................................................................................................ 6429
Aftermarket Electrical and Vacuum Equipment......................................................................................... 6429
Electrostatic Discharge Damage...................................................................................................... 6429
General Description (Air Induction)..................................................................................................... 6430
Air Induction System................................................................................................................ 6430
General Description (Fuel Metering)..................................................................................................... 6430
Acceleration Mode................................................................................................................... 6430
Accelerator Controls................................................................................................................ 6430
Battery Voltage Correction Mode..................................................................................................... 6430
CMP Signal.......................................................................................................................... 6430
Clear Flood Mode.................................................................................................................... 6430
Deceleration Mode................................................................................................................... 6430
Engine Speed/Fuel Disable Mode...................................................................................................... 6430
Fuel Cutoff Mode.................................................................................................................... 6430
Fuel Injector....................................................................................................................... 6430
Fuel Metering System Components..................................................................................................... 6431
Fuel Metering System Purpose........................................................................................................ 6431
Fuel Pressure Regulator............................................................................................................. 6431
Fuel Pump Electrical Circuit........................................................................................................ 6431
Fuel Rail........................................................................................................................... 6431
Idle Air Control (IAC) Valve........................................................................................................ 6432
Run Mode............................................................................................................................ 6432
Starting Mode....................................................................................................................... 6432
Throttle Body Unit.................................................................................................................. 6433
General Description (Electronic Ignition System)........................................................................................ 6433
Camshaft Position (CMP) Sensor...................................................................................................... 6433
Crankshaft Position (CKP) Sensor.................................................................................................... 6433
Electronic Ignition................................................................................................................. 6434
Ignition Coils...................................................................................................................... 6434
Ignition Control.................................................................................................................... 6434
Knock Sensor (KS) PCM Input......................................................................................................... 6435
Powertrain Control Module (PCM)..................................................................................................... 6435
Spark Plug.......................................................................................................................... 6435
A/C Clutch Diagnosis.................................................................................................................... 6437
A/C Clutch Circuit Operation........................................................................................................ 6437
A/C Clutch Circuit Purpose.......................................................................................................... 6437
A/C Request Signal.................................................................................................................. 6437
General Description (Evaporative (EVAP) Emission System)................................................................................ 6438
EVAP Emission Control System Purpose................................................................................................ 6438
EVAP Emission Control System Operation.............................................................................................. 6438
Enhanced Evaporative Emission Control System........................................................................................ 6439
General Description (Exhaust Gas Recirculation (EGR) System)............................................................................ 6442
EGR Purpose......................................................................................................................... 6442
Linear EGR Valve.................................................................................................................... 6442
Linear EGR Control.................................................................................................................. 6442
Linear EGR Valve Operation and Results of Incorrect Operation....................................................................... 6442
EGR Pintle Position Sensor.......................................................................................................... 6442
General Description (Positive Crankcase Ventilation (PCV) System)....................................................................... 6443
Crankcase Ventilation System Purpose................................................................................................ 6443
Crankcase Ventilation System Operation.............................................................................................. 6443
Special Tools........................................................................................................................... 6444
6F ENGINE EXHAUST......................................................................................................................... 6446
General Description..................................................................................................................... 6447
Three Way Catalytic Converter LH........................................................................................................ 6448
Removal............................................................................................................................. 6448
Installation........................................................................................................................ 6448
Three Way Catalytic Converter RH........................................................................................................ 6449
Removal............................................................................................................................. 6449
Installation........................................................................................................................ 6449
Exhaust Silencer........................................................................................................................ 6450
Exhaust Silencer and Associated Parts............................................................................................... 6450
Removal............................................................................................................................. 6450
Installation........................................................................................................................ 6450
Rear Exhaust pipe....................................................................................................................... 6451
Rear Exhaust pipe and Associated Parts.............................................................................................. 6451
Removal............................................................................................................................. 6451
Installation........................................................................................................................ 6451
Main Data and Specifications............................................................................................................ 6452
6G ENGINE LUBRICATION..................................................................................................................... 6453
Service Precaution...................................................................................................................... 6453
General Description..................................................................................................................... 6454
Oil Pump................................................................................................................................ 6455
Oil Pump and Associated Parts....................................................................................................... 6455
Oil Pump and Associated Parts....................................................................................................... 6455
Inspection and Repair............................................................................................................... 6456
Reassembly.......................................................................................................................... 6457
Oil Pan and Crankcase................................................................................................................... 6459
Removal............................................................................................................................. 6459
Installation........................................................................................................................ 6459
Oil Pump................................................................................................................................ 6461
Removal............................................................................................................................. 6461
Installation........................................................................................................................ 6461
Oil Pump Oil Seal....................................................................................................................... 6463
Removal............................................................................................................................. 6463
Installation........................................................................................................................ 6463
Oil Filter.............................................................................................................................. 6464
Removal............................................................................................................................. 6464
Installation........................................................................................................................ 6464
Main Data and Specification............................................................................................................. 6465
Special Tool............................................................................................................................ 6466
6H ENGINE SPEED CONTROL SYSTEM............................................................................................................ 6467
Service Precaution...................................................................................................................... 6467
Accelerator Pedal Control Cable......................................................................................................... 6468
Removal............................................................................................................................. 6468
Inspection.......................................................................................................................... 6468
Installation........................................................................................................................ 6468
Accelerator Pedal....................................................................................................................... 6469
Accelerator Pedal and Associated Parts.............................................................................................. 6469
Removal............................................................................................................................. 6469
Installation........................................................................................................................ 6469
6J INDUCTION.............................................................................................................................. 6470
Service Precaution...................................................................................................................... 6470
Air Cleaner Element..................................................................................................................... 6471
Removal............................................................................................................................. 6471
Inspection.......................................................................................................................... 6471
Installation........................................................................................................................ 6471
Sec.7 TRANSMISSION............................................................................................................................ 6472
7A AUTOMATIC TRANSMISSION (4L30-E)........................................................................................................ 6472
Service Precaution...................................................................................................................... 6474
Construction............................................................................................................................ 6474
Range Reference Chart................................................................................................................... 6475
Normal Operation Of 1999 4L30-E Transmission............................................................................................ 6476
Diagnosis............................................................................................................................... 6476
Driver Information...................................................................................................................... 6476
General Diagnosis Procedure............................................................................................................. 6479
Preliminary Inspection Chart............................................................................................................ 6480
Checking Transmission Fluid Level and Condition......................................................................................... 6481
Test Driving............................................................................................................................ 6482
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................ 6483
Mechanical / Hydraulic Diagnosis Symptoms Index......................................................................................... 6484
Stall Test.............................................................................................................................. 6494
Line Pressure Test...................................................................................................................... 6494
Shift Speed Chart....................................................................................................................... 6495
Lockup Speed Chart...................................................................................................................... 6497
Changing Transmission Fluid............................................................................................................. 6498
Selector Lever.......................................................................................................................... 6498
Inspection.......................................................................................................................... 6498
Removal............................................................................................................................. 6499
Installation........................................................................................................................ 6499
Mode Switch............................................................................................................................. 6500
Removal............................................................................................................................. 6500
Installation........................................................................................................................ 6500
Transmission (With Transfer Case)....................................................................................................... 6502
Transmission And Associated Parts................................................................................................... 6502
Removal............................................................................................................................. 6502
Installation........................................................................................................................ 6506
Solenoid (Main Case Valve Body)......................................................................................................... 6510
Removal............................................................................................................................. 6510
Installation........................................................................................................................ 6510
Solenoid (Adapter Case Valve Body)...................................................................................................... 6511
Removal............................................................................................................................. 6511
Installation........................................................................................................................ 6511
Valve Body Assembly (Main Case)......................................................................................................... 6512
Removal............................................................................................................................. 6512
Installation........................................................................................................................ 6512
Valve Body Assembly (Adapter Case)...................................................................................................... 6514
Removal............................................................................................................................. 6514
Installation........................................................................................................................ 6514
Powertrain Control Module (PCM)......................................................................................................... 6514
Removal............................................................................................................................. 6514
Installation........................................................................................................................ 6514
Speed Sensor (Extension Housing)........................................................................................................ 6515
Removal............................................................................................................................. 6515
Installation........................................................................................................................ 6515
Transmission Oil Temperature Sensor (Adapter Case)...................................................................................... 6515
Removal............................................................................................................................. 6515
Installation........................................................................................................................ 6515
Front Oil Seal (Converter Housing)...................................................................................................... 6516
Removal............................................................................................................................. 6516
Installation........................................................................................................................ 6516
Rear Oil Seal (Extension Housing)....................................................................................................... 6516
Removal............................................................................................................................. 6516
Installation........................................................................................................................ 6517
Transmission (4L30-E)................................................................................................................... 6517
Disassembly......................................................................................................................... 6517
Reassembly.......................................................................................................................... 6521
Converter Housing And Oil Pump Assembly................................................................................................. 6532
Disassembled View................................................................................................................... 6532
Disassembly......................................................................................................................... 6532
Inspection And Repair............................................................................................................... 6532
Reassembly.......................................................................................................................... 6532
Oil Pump................................................................................................................................ 6533
Disassembled View................................................................................................................... 6533
Disassembly......................................................................................................................... 6533
Inspection And Repair............................................................................................................... 6533
Reassembly.......................................................................................................................... 6533
Main Case Valve Body.................................................................................................................... 6534
Disassembled View................................................................................................................... 6534
Disassembly......................................................................................................................... 6534
Inspection And Repair............................................................................................................... 6535
Reassembly.......................................................................................................................... 6535
Adapter Case Valve Body................................................................................................................. 6536
Disassembled View................................................................................................................... 6536
Disassembly......................................................................................................................... 6536
Inspection And Repair............................................................................................................... 6536
Reassembly.......................................................................................................................... 6536
Third Clutch And Sprag Unit............................................................................................................. 6538
Disassembled View................................................................................................................... 6538
Disassembly......................................................................................................................... 6538
Inspection And Repair............................................................................................................... 6539
Reassembly.......................................................................................................................... 6539
Third Clutch............................................................................................................................ 6540
Disassembled View................................................................................................................... 6540
Disassemble......................................................................................................................... 6540
Inspection And Repair............................................................................................................... 6540
Reassembly.......................................................................................................................... 6540
Sprag Unit.............................................................................................................................. 6542
Disassembled View................................................................................................................... 6542
Disassembly......................................................................................................................... 6542
Inspection And Repair............................................................................................................... 6542
Reassembly.......................................................................................................................... 6542
Second Clutch........................................................................................................................... 6543
Disassembled View................................................................................................................... 6543
Disassembly......................................................................................................................... 6543
Inspection And Repair............................................................................................................... 6544
Reassembly.......................................................................................................................... 6544
3-4 Accumulator Piston.................................................................................................................. 6545
Disassembled View................................................................................................................... 6545
Disassembly......................................................................................................................... 6545
Inspection And Repair............................................................................................................... 6545
Reassembly.......................................................................................................................... 6546
Reverse Clutch Piston And Center Support................................................................................................ 6547
Disassembled View................................................................................................................... 6547
Disassembly......................................................................................................................... 6547
Inspection And Repair............................................................................................................... 6548
Reassembly.......................................................................................................................... 6548
Overrun Clutch And Turbine Shaft........................................................................................................ 6549
Disassembled View................................................................................................................... 6549
Disassembly......................................................................................................................... 6549
Inspection And Repair............................................................................................................... 6550
Reassembly.......................................................................................................................... 6550
Main Data And Specification............................................................................................................. 6552
Special Tools........................................................................................................................... 6556
4L30-E Parts List....................................................................................................................... 6559
7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)................................................................................................... 6567
Service Precaution...................................................................................................................... 6568
General Description..................................................................................................................... 6568
Electronic Control Diagram.......................................................................................................... 6569
Powertrain Control Module (PCM)..................................................................................................... 6570
Control System Diagram.............................................................................................................. 6571
Shift Control....................................................................................................................... 6572
Band Apply Control.................................................................................................................. 6572
Torque Converter Clutch Control..................................................................................................... 6572
Line Pressure Control............................................................................................................... 6572
On-Board Diagnostic System.......................................................................................................... 6572
Fail Safe Mechanism................................................................................................................. 6572
Torque Management Control........................................................................................................... 6572
ATF Warning Control................................................................................................................. 6572
ABS Control......................................................................................................................... 6572
Shift Mode Control.................................................................................................................. 6573
Gear Shift Control.................................................................................................................. 6574
Winter Drive Mode................................................................................................................... 6575
Backup Mode......................................................................................................................... 6575
Functions of Input / Output Components.............................................................................................. 6576
Diagnosis............................................................................................................................... 6577
Electronic Diagnosis................................................................................................................ 6577
How To Diagnose The Problem......................................................................................................... 6577
Check Trans Indicator............................................................................................................... 6577
Diagnostic Check.................................................................................................................... 6577
"Check Trans" Check................................................................................................................. 6578
Tech 2 OBD II Connection............................................................................................................ 6579
F0: Transmission Data............................................................................................................... 6583
F1: PC Solenoid Data................................................................................................................ 6584
OBD II Diagnostic Management System................................................................................................. 6585
16-Terminal Data Link Connector (DLC)............................................................................................... 6586
Malfunction Indicator Lamp (MIL).................................................................................................... 6587
Types Of Diagnostic Trouble Codes (DTCs)............................................................................................ 6587
Clear DTC........................................................................................................................... 6587
DTC Check........................................................................................................................... 6588
PCM Precaution...................................................................................................................... 6588
Information On PCM.................................................................................................................. 6588
Intermittent Conditions............................................................................................................. 6588
Transmission And PCM Identification................................................................................................. 6589
Diagnostic Trouble Code (DTC) Identification........................................................................................ 6590
DTC P0218 Transmission Fluid Over Temperature........................................................................................... 6591
DTC P0560 System Voltage Malfunction.................................................................................................... 6593
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position...................................................................... 6596
DTC P0706 Transmission Range Switch (Mode Switch) Performance........................................................................... 6599
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Circuit Range/Performance......................................................... 6602
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input................................................................. 6605
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................ 6608
DTC P0719 TCC Brake Switch Circuit High (Stuck On)...................................................................................... 6611
DTC P0722 Transmission Output Speed Sensor (OSS) Low Input.............................................................................. 6614
DTC P0723 Transmission Output Speed Sensor (OSS) Intermittent........................................................................... 6617
DTC P0724 TCC Brake Switch Circuit Low (Stuck Off)...................................................................................... 6620
DTC P0730 Transmission Incorrect Gear Ratio............................................................................................. 6622
DTC P0742 Torque Converter Clutch (TCC) Circuit Stuck On................................................................................ 6625
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical.............................................................. 6627
DTC P0751 Shift Solenoid A Performance Without Input Speed.............................................................................. 6629
DTC P0753 Shift Solenoid A Electrical................................................................................................... 6631
DTC P0756 Shift Solenoid B Performance Without Input Speed.............................................................................. 6634
DTC P0758 Shift Solenoid B Electrical................................................................................................... 6636
DTC P1790 ROM Transmission Side Bad Check Sum........................................................................................... 6640
DTC P1792 EEPROM Transmission Side Bad Check Sum........................................................................................ 6641
DTC P1835 Kickdown Switch Always On..................................................................................................... 6642
DTC P1850 Brake Band Apply Solenoid Malfunction......................................................................................... 6644
DTC P1860 TCC Solenoid Electrical....................................................................................................... 6648
DTC P1870 Transmission Component Slipping............................................................................................... 6651
Circuit Diagram......................................................................................................................... 6653
Parts Location.......................................................................................................................... 6655
Harness Connector Faces................................................................................................................. 6656
Sec.8 BODY AND ACCESSORIES.................................................................................................................... 6821
8A LIGHTING SYSTEM........................................................................................................................ 6658
Service Precaution...................................................................................................................... 6659
Headlight Bulb.......................................................................................................................... 6659
Removal............................................................................................................................. 6659
Installation........................................................................................................................ 6659
Headlight............................................................................................................................... 6660
Removal............................................................................................................................. 6660
Installation........................................................................................................................ 6660
Headlight Adjustment................................................................................................................ 6660
Fender Marker Light Bulb................................................................................................................ 6662
Removal............................................................................................................................. 6662
Installation........................................................................................................................ 6662
Front Side Marker Light Bulb............................................................................................................ 6662
Removal............................................................................................................................. 6662
Installation........................................................................................................................ 6662
Rear Side Marker Light Bulb............................................................................................................. 6663
Removal............................................................................................................................. 6663
Installation........................................................................................................................ 6663
Parking Light Bulb...................................................................................................................... 6663
Removal............................................................................................................................. 6663
Installation........................................................................................................................ 6663
Taillight Bulb.......................................................................................................................... 6664
Removal............................................................................................................................. 6664
Installation........................................................................................................................ 6664
License Plate Light Bulb................................................................................................................ 6664
Removal............................................................................................................................. 6664
Installation........................................................................................................................ 6664
Stoplight Bulb.......................................................................................................................... 6665
Removal and Installation............................................................................................................ 6665
High Mounted Stop Light................................................................................................................. 6665
Removal............................................................................................................................. 6665
Installation........................................................................................................................ 6665
Front Turn Signal Light Bulb............................................................................................................ 6666
Removal............................................................................................................................. 6666
Installation........................................................................................................................ 6666
Rear Turn Signal Light Bulb............................................................................................................. 6666
Removal............................................................................................................................. 6666
Installation........................................................................................................................ 6666
Backup Light Bulb....................................................................................................................... 6667
Removal............................................................................................................................. 6667
Installation........................................................................................................................ 6667
Dome Light Bulb......................................................................................................................... 6667
Removal............................................................................................................................. 6667
Installation........................................................................................................................ 6667
Map Light Switch/Bulb................................................................................................................... 6668
Removal............................................................................................................................. 6668
Installation........................................................................................................................ 6668
Cigarette Lighter Illumination Bulb..................................................................................................... 6668
Removal............................................................................................................................. 6668
Installation........................................................................................................................ 6668
Ashtray Illumination Bulb............................................................................................................... 6669
Removal............................................................................................................................. 6669
Installation........................................................................................................................ 6669
HVAC Bezel Illumination Light Bulb...................................................................................................... 6669
Removal and Installation............................................................................................................ 6669
Shift Lever Illumination Light Bulb (A/T)............................................................................................... 6670
Removal............................................................................................................................. 6670
Installation........................................................................................................................ 6670
Starter Switch.......................................................................................................................... 6670
Removal............................................................................................................................. 6670
Installation........................................................................................................................ 6670
Lighting Switch (Combination Switch).................................................................................................... 6671
Removal............................................................................................................................. 6671
Installation........................................................................................................................ 6671
Stoplight Switch........................................................................................................................ 6672
Removal............................................................................................................................. 6672
Installation........................................................................................................................ 6672
Turn Signal Switch(Combination Switch).................................................................................................. 6673
Removal and Installation............................................................................................................ 6673
Hazard Warning Switch................................................................................................................... 6673
Removal............................................................................................................................. 6673
Installation........................................................................................................................ 6673
Key Remind Switch(Starter Switch)....................................................................................................... 6673
Removal and Installation............................................................................................................ 6673
Door Switch............................................................................................................................. 6674
Removal............................................................................................................................. 6674
Installation........................................................................................................................ 6674
Rear Defogger Switch.................................................................................................................... 6674
Removal............................................................................................................................. 6674
Installation........................................................................................................................ 6674
Illumination Controller................................................................................................................. 6675
Removal............................................................................................................................. 6675
Installation........................................................................................................................ 6675
Main Data and Specifications............................................................................................................ 6676
8B WIPER / WASHER SYSTEM.................................................................................................................. 6679
Service Precaution...................................................................................................................... 6679
Windshield Wiper/Washer System.......................................................................................................... 6680
General Description................................................................................................................. 6680
Windshield Wiper And Washer Switch...................................................................................................... 6680
Removal and Installation............................................................................................................ 6680
Windshield Wiper Motor.................................................................................................................. 6680
Removal............................................................................................................................. 6680
Installation........................................................................................................................ 6680
Windshield Washer Motor................................................................................................................. 6681
Removal............................................................................................................................. 6681
Installation........................................................................................................................ 6681
Washer Nozzle Angle Adjustment...................................................................................................... 6681
Windshield Wiper Linkage................................................................................................................ 6682
Windshield Wiper Linkage and Associated Parts....................................................................................... 6682
Removal............................................................................................................................. 6682
Installation........................................................................................................................ 6682
Windshield Wiper Arm/Blade.............................................................................................................. 6683
Removal............................................................................................................................. 6683
Installation........................................................................................................................ 6683
Windshield Wiper Blade Rubber........................................................................................................... 6684
Removal............................................................................................................................. 6684
Installation........................................................................................................................ 6684
Alarm & Relay Control Unit.............................................................................................................. 6685
Removal............................................................................................................................. 6685
Installation........................................................................................................................ 6685
Intermittent Relay...................................................................................................................... 6685
Removal............................................................................................................................. 6685
Installation........................................................................................................................ 6685
Main Data and Specifications............................................................................................................ 6686
8C ENTERTAINMENT.......................................................................................................................... 6687
Service Precaution...................................................................................................................... 6687
Cigarette Lighter....................................................................................................................... 6688
General Description................................................................................................................. 6688
Removal............................................................................................................................. 6688
Installation........................................................................................................................ 6688
Antenna................................................................................................................................. 6689
Removal............................................................................................................................. 6689
Installation........................................................................................................................ 6689
Radio................................................................................................................................... 6690
Removal............................................................................................................................. 6690
Installation........................................................................................................................ 6690
Front Speaker........................................................................................................................... 6690
Removal............................................................................................................................. 6690
Installation........................................................................................................................ 6690
Tweeter Assembly........................................................................................................................ 6691
Removal............................................................................................................................. 6691
Installation........................................................................................................................ 6691
Rear Speaker............................................................................................................................ 6691
Removal............................................................................................................................. 6691
Installation........................................................................................................................ 6691
Horn (Low note)......................................................................................................................... 6692
Removal............................................................................................................................. 6692
Installation........................................................................................................................ 6692
Horn (High note)........................................................................................................................ 6692
Removal............................................................................................................................. 6692
Installation........................................................................................................................ 6692
8D WIRING SYSTEM.......................................................................................................................... 6693
Fuse, Relay and Diode................................................................................................................... 6694
Relay and Fuse Box / Relay Box Location............................................................................................. 6694
Fuse Layout......................................................................................................................... 6695
Relay Layout........................................................................................................................ 6696
Diode Layout........................................................................................................................ 6697
Circuit Diagram......................................................................................................................... 6698
Harness and Connector Location.......................................................................................................... 6719
8E METER AND GAUGE........................................................................................................................ 6738
Service Precaution...................................................................................................................... 6738
Meter Assembly.......................................................................................................................... 6739
General Description................................................................................................................. 6739
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights.................................................. 6739
Table for Meter/Gauge Connector Terminal Connections................................................................................ 6741
Removal............................................................................................................................. 6743
Installation........................................................................................................................ 6743
Speedometer............................................................................................................................. 6744
Removal............................................................................................................................. 6744
Installation........................................................................................................................ 6744
Tachometer.............................................................................................................................. 6745
Removal............................................................................................................................. 6745
Installation........................................................................................................................ 6745
Coolant Temperature gauge and Fuel Gauge................................................................................................ 6746
Removal............................................................................................................................. 6746
Installation........................................................................................................................ 6746
TOD Indicator Assembly.................................................................................................................. 6747
Removal............................................................................................................................. 6747
Installation........................................................................................................................ 6747
Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb....................................................................... 6748
Removal............................................................................................................................. 6748
Installation........................................................................................................................ 6748
A/T Indicator Light Bulb................................................................................................................ 6748
Removal............................................................................................................................. 6748
Installation........................................................................................................................ 6748
Vehicle Speed Sensor.................................................................................................................... 6749
Removal............................................................................................................................. 6749
Installation........................................................................................................................ 6749
Thermo Unit............................................................................................................................. 6749
Removal............................................................................................................................. 6749
Installation........................................................................................................................ 6749
Fuel Tank Unit.......................................................................................................................... 6750
Removal............................................................................................................................. 6750
Installation........................................................................................................................ 6750
Main Data and Specifications............................................................................................................ 6751
8F BODY STRUCTURE......................................................................................................................... 6752
Service Precaution...................................................................................................................... 6753
Frame................................................................................................................................... 6753
General Description................................................................................................................. 6753
Frame Dimensions.................................................................................................................... 6754
Front Bumper............................................................................................................................ 6755
Parts Location...................................................................................................................... 6755
Removal............................................................................................................................. 6756
Installation........................................................................................................................ 6756
Rear Bumper............................................................................................................................. 6757
Parts Location...................................................................................................................... 6757
Removal............................................................................................................................. 6757
Installation........................................................................................................................ 6757
Engine Hood............................................................................................................................. 6758
Parts Location...................................................................................................................... 6758
Removal............................................................................................................................. 6758
Installation........................................................................................................................ 6759
Engine Hood Cover....................................................................................................................... 6760
Parts Location...................................................................................................................... 6760
Removal............................................................................................................................. 6760
Installation........................................................................................................................ 6760
Engine Hood Lock........................................................................................................................ 6761
Parts Location...................................................................................................................... 6761
Removal............................................................................................................................. 6761
Installation........................................................................................................................ 6762
Radiator Grille......................................................................................................................... 6762
Parts Location...................................................................................................................... 6762
Removal............................................................................................................................. 6762
Installation........................................................................................................................ 6762
Front Fender Panel...................................................................................................................... 6763
Parts Location...................................................................................................................... 6763
Removal............................................................................................................................. 6763
Installation........................................................................................................................ 6764
Body Mounting........................................................................................................................... 6765
Parts Location...................................................................................................................... 6765
Tightening Torque................................................................................................................... 6765
Body Dimension...................................................................................................................... 6766
Instrument Panel Assembly and Cross Beam Assembly....................................................................................... 6776
Parts Location...................................................................................................................... 6776
Removal............................................................................................................................. 6777
Installation........................................................................................................................ 6780
Front Door Assembly..................................................................................................................... 6782
Parts Location...................................................................................................................... 6782
Removal............................................................................................................................. 6782
Installation........................................................................................................................ 6783
Door Strikers........................................................................................................................... 6784
Adjustment.......................................................................................................................... 6784
Front Window Regulator, Glass and Glass Run............................................................................................. 6785
Parts Location...................................................................................................................... 6785
Removal............................................................................................................................. 6786
Installation........................................................................................................................ 6788
Tailgate Assembly....................................................................................................................... 6789
Parts Location...................................................................................................................... 6789
Removal............................................................................................................................. 6789
Installation........................................................................................................................ 6790
Tailgate Dove-Tail...................................................................................................................... 6791
Parts Location...................................................................................................................... 6791
Removal............................................................................................................................. 6791
Installation........................................................................................................................ 6791
Spare Tire Carrier...................................................................................................................... 6792
Parts Location...................................................................................................................... 6792
Removal............................................................................................................................. 6792
Installation........................................................................................................................ 6792
Windshield.............................................................................................................................. 6793
Parts Location...................................................................................................................... 6793
Removal............................................................................................................................. 6793
Installation........................................................................................................................ 6794
Rear Quarter............................................................................................................................ 6798
Parts Location...................................................................................................................... 6798
Removal............................................................................................................................. 6798
Installation........................................................................................................................ 6799
Center Glass............................................................................................................................ 6800
Parts Location...................................................................................................................... 6800
Removal............................................................................................................................. 6800
Installation........................................................................................................................ 6801
Tailgate Glass.......................................................................................................................... 6802
Parts Location...................................................................................................................... 6802
Removal............................................................................................................................. 6802
Installation........................................................................................................................ 6802
Main Data and Specifications............................................................................................................ 6804
8G SEATS.................................................................................................................................. 6805
Service Precaution...................................................................................................................... 6805
Front Seat Assembly..................................................................................................................... 6806
Disassembled View................................................................................................................... 6806
Removal............................................................................................................................. 6806
Installation........................................................................................................................ 6807
Disassembly......................................................................................................................... 6807
Reassembly.......................................................................................................................... 6807
Rear Seat Assembly...................................................................................................................... 6808
Disassembled View................................................................................................................... 6808
Removal............................................................................................................................. 6808
Installation........................................................................................................................ 6808
Disassembly......................................................................................................................... 6809
Reassembly.......................................................................................................................... 6809
Main Data and Specifications............................................................................................................ 6810
8H SECURITY AND LOCKS..................................................................................................................... 6811
Service Precaution...................................................................................................................... 6811
Front Door Lock Assembly................................................................................................................ 6812
Front Door Lock Assembly and Associated Parts....................................................................................... 6812
Removal............................................................................................................................. 6812
Installation........................................................................................................................ 6813
Front Outside Handle and Door Lock Cylinder............................................................................................. 6814
Front Outside Handle, Door Lock Cylinder and Associated Parts....................................................................... 6814
Removal............................................................................................................................. 6814
Installation........................................................................................................................ 6815
Tailgate Lock and Lock Cylinder......................................................................................................... 6816
Tailgate Lock, Lock Cylinder and Associated Parts................................................................................... 6816
Removal............................................................................................................................. 6816
Installation........................................................................................................................ 6817
Key..................................................................................................................................... 6818
Key Coding.......................................................................................................................... 6818
Key Styles.......................................................................................................................... 6818
Power Door Lock System.................................................................................................................. 6819
General Description................................................................................................................. 6819
Front Door Lock Actuator Removal.................................................................................................... 6819
Front Door Lock Actuator Installation............................................................................................... 6819
Main Data and Specifications............................................................................................................ 6820
8J EXTERIOR / INTERIOR TRIM............................................................................................................... 6821
Service Precaution...................................................................................................................... 6821
Consoles................................................................................................................................ 6822
Consoles and Associated Parts....................................................................................................... 6822
Removal............................................................................................................................. 6822
Installation........................................................................................................................ 6822
Front Door Trim Assembly................................................................................................................ 6823
Front Door Trim Assembly and Associated Parts....................................................................................... 6823
Removal............................................................................................................................. 6823
Installation........................................................................................................................ 6824
Door Mirror............................................................................................................................. 6824
Door Mirror and Associated Parts.................................................................................................... 6824
Removal............................................................................................................................. 6824
Installation........................................................................................................................ 6824
Interior Trim Cover and Assist Grip..................................................................................................... 6825
Interior Trim Cover, Assist Grip and Associated Parts............................................................................... 6825
Removal............................................................................................................................. 6825
Installation........................................................................................................................ 6826
Headlining.............................................................................................................................. 6827
Parts Location...................................................................................................................... 6827
Removal............................................................................................................................. 6827
Installation........................................................................................................................ 6828
Tailgate Trim Cover..................................................................................................................... 6828
Tailgate Trim Cover and Associated Parts............................................................................................ 6828
Removal............................................................................................................................. 6828
Installation........................................................................................................................ 6828
Body Side Protectors.................................................................................................................... 6829
Body Side Protectors and Associated Parts........................................................................................... 6829
Removal............................................................................................................................. 6830
Installation........................................................................................................................ 6830
Tailgate Protector...................................................................................................................... 6831
Parts Location...................................................................................................................... 6831
Removal............................................................................................................................. 6831
Installation........................................................................................................................ 6831
Fuel Filler Lid......................................................................................................................... 6832
Parts Location...................................................................................................................... 6832
Removal............................................................................................................................. 6832
Installation........................................................................................................................ 6832
Roof Rail Assembly...................................................................................................................... 6833
Parts Location...................................................................................................................... 6833
Removal............................................................................................................................. 6833
Installation........................................................................................................................ 6833
Rear Roof Spoiler....................................................................................................................... 6834
Parts Location...................................................................................................................... 6834
Removal............................................................................................................................. 6834
Installation........................................................................................................................ 6834
Power Door Mirror System................................................................................................................ 6835
General Description................................................................................................................. 6835
Door Mirror Control Switch and Door Mirror Defogger Switch Removal.................................................................. 6835
Installation........................................................................................................................ 6835
Power Door Mirror....................................................................................................................... 6835
General Description................................................................................................................. 6835
Removal and Installation............................................................................................................ 6835
Power Window System..................................................................................................................... 6836
General Description................................................................................................................. 6836
Power Window Switch Removal and Installation........................................................................................ 6836
Power Window Motor Removal and Installation......................................................................................... 6837
Main Data and Specifications............................................................................................................ 6838
Sec.9 RESTRAINTS.............................................................................................................................. 6839
9A SEAT BELT SYSTEM....................................................................................................................... 6839
Service Precaution...................................................................................................................... 6839
Front Seat Belt......................................................................................................................... 6840
Front Seat Belt and Associated Parts................................................................................................ 6840
Removal............................................................................................................................. 6840
Inspection.......................................................................................................................... 6840
Installation........................................................................................................................ 6841
Rear Seat Belt.......................................................................................................................... 6842
Rear Seat Belt and Associated Parts................................................................................................. 6842
Removal............................................................................................................................. 6842
Inspection.......................................................................................................................... 6843
Installation........................................................................................................................ 6843
Front Seat Belt Buckle Assembly......................................................................................................... 6844
Front Seat Belt Buckle Assembly and Associated Parts................................................................................ 6844
Removal............................................................................................................................. 6844
Installation........................................................................................................................ 6844
Rear Seat Belt Buckle Assembly.......................................................................................................... 6845
Removal............................................................................................................................. 6845
Installation........................................................................................................................ 6845
Child Seat Tether Anchor Bracket (Child Restraint)...................................................................................... 6846
General Description................................................................................................................. 6846
Child Seat Tether Anchor Bracket and Associated Parts............................................................................... 6846
Installation........................................................................................................................ 6846
Main Data and Specifications............................................................................................................ 6847
9J SUPPLEMENTAL RESTRAINT SYSTEM.......................................................................................................... 6848
Service Precaution...................................................................................................................... 6848
General Description..................................................................................................................... 6849
SRS Component and Wiring Location View.............................................................................................. 6851
Component Description................................................................................................................... 6851
Definition.............................................................................................................................. 6854
Diagnosis............................................................................................................................... 6855
SRS Connector Body Face Views........................................................................................................... 6856
Repairs and Inspections Required After an Accident...................................................................................... 6856
On-Vehicle Service...................................................................................................................... 6857
Air Bag Assembly Handling / Shipping / Scrapping........................................................................................ 6858
Special Tools........................................................................................................................... 6874
Service Precaution...................................................................................................................... 6879
Sensing and Diagnostic Module (SDM)..................................................................................................... 6881
Service Precautions................................................................................................................. 6881
Removal............................................................................................................................. 6881
Installation........................................................................................................................ 6881
Driver Air Bag Assembly................................................................................................................. 6883
Service Precautions................................................................................................................. 6883
Removal............................................................................................................................. 6883
Installation........................................................................................................................ 6883
Steering Wheel.......................................................................................................................... 6884
Service Precautions................................................................................................................. 6884
Removal............................................................................................................................. 6884
Installation........................................................................................................................ 6885
SRS Coil Assembly....................................................................................................................... 6886
Service Precaution.................................................................................................................. 6886
Removal............................................................................................................................. 6886
Installation........................................................................................................................ 6887
Steering Column......................................................................................................................... 6889
Service Precaution.................................................................................................................. 6889
Removal............................................................................................................................. 6889
Installation........................................................................................................................ 6891
Passenger Air Bag Assembly.............................................................................................................. 6893
Service Precaution.................................................................................................................. 6893
Removal............................................................................................................................. 6893
Installation........................................................................................................................ 6893
Main Data and Specifications............................................................................................................ 6894
SRS Air Bag System Inspection Standards For Repair...................................................................................... 6895
9J1 SRS CONTROL SYSTEM..................................................................................................................... 6896
Service Precaution...................................................................................................................... 6896
Diagnostic Information.................................................................................................................. 6897
Parts For Electrical Circuit............................................................................................................ 6899
System Schematic........................................................................................................................ 6900
SRS Diagnostic System Check............................................................................................................. 6900
Chart A SDM Integrity Check............................................................................................................. 6903
Chart B "AIR BAG" Warning Lamp Comes "ON" Steady........................................................................................ 6905
Chart C "AIR BAG" Warning Lamp Does Not Comes "ON" Steady............................................................................... 6907
DTC 15 Passenger Deployment Loop Resistance High........................................................................................ 6910
DTC 16 Passenger Deployment Loop Resistance Low......................................................................................... 6913
DTC 17 Passenger Deployment Loop Open................................................................................................... 6916
DTC 18 Passenger Deployment Loop Short To Ground........................................................................................ 6918
DTC 19 Passenger Deployment Loop Short To Voltage....................................................................................... 6920
DTC 21 Driver Deployment Loop Resistance High........................................................................................... 6922
DTC 22 Driver Deployment Loop Resistance Low............................................................................................ 6925
DTC 24 Driver Deployment Loop Short To Ground........................................................................................... 6928
DTC 25 Driver Deployment Loop Short To Voltage.......................................................................................... 6930
DTC 26 Driver Deployment Loop Open...................................................................................................... 6933
DTC 51 Deployment Event Commanded....................................................................................................... 6936
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range.................................................. 6938
DTC 61 Warning Lamp Circuit Failure..................................................................................................... 6940
DTC 71 Internal SDM Fault............................................................................................................... 6942
Sec.10 CONTROL SYSTEM.......................................................................................................................... 6944
10A CRUISE CONTROL SYSTEM.................................................................................................................. 6944
Service Precaution...................................................................................................................... 6944
General Description..................................................................................................................... 6945
Diagnosis............................................................................................................................... 6945
Brake Switch............................................................................................................................ 6946
Removal and Installation............................................................................................................ 6946
Adjustment.......................................................................................................................... 6946
Cruise Control Unit..................................................................................................................... 6946
Removal............................................................................................................................. 6946
Installation........................................................................................................................ 6946
Cruise Actuator......................................................................................................................... 6947
Actuator Cable Diagram.............................................................................................................. 6947
Removal............................................................................................................................. 6947
Installation........................................................................................................................ 6948
Adjustment.......................................................................................................................... 6948
Mode Switch............................................................................................................................. 6949
Removal and Installation............................................................................................................ 6949
Cruise Control Main Switch.............................................................................................................. 6949
Removal............................................................................................................................. 6949
Installation........................................................................................................................ 6949
Cruise Control Switch (Combination Switch).............................................................................................. 6949
Removal and Installation............................................................................................................ 6949
2000 MODEL.............................................................................................................................................. 2
(UX) TROOPER........................................................................................................................................ 6950
Sec.0 GENERAL INFORMATION..................................................................................................................... 6951
0A GENERAL INFORMATION..................................................................................................................... 6951
General Repair Instruction.............................................................................................................. 6951
Illustration Arrows..................................................................................................................... 6952
Identification.......................................................................................................................... 6953
Theft Prevention Standard............................................................................................................... 6955
Lifting Instructions.................................................................................................................... 6960
Standard Bolts Torque Specifications.................................................................................................... 6963
Abbreviations Charts.................................................................................................................... 6964
Service Parts Identification Plate...................................................................................................... 6965
0B MAINTENANCE AND LUBRICATION............................................................................................................. 6966
Maintenance Schedule List............................................................................................................... 6966
Explanation of Complete Vehicle Maintenance Schedule.................................................................................... 6970
Recommended Fluids and Lubricants................................................................................................... 6973
Lubricant Viscosity Chart............................................................................................................... 6974
Recommended Liquid Gasket........................................................................................................... 6976
Recommended Thread Locking Agents................................................................................................... 6977
Maintenance Service Data................................................................................................................ 6978
Sec.1 HEATING, VENTILATION AND AIR............................................................................................................ 6979
1A HVAC SYSTEMS............................................................................................................................ 6979
Service Precaution...................................................................................................................... 6981
Heating and Ventilation System.......................................................................................................... 6981
General Description..................................................................................................................... 6981
Wiring Diagram.......................................................................................................................... 6986
Diagnosis............................................................................................................................... 6987
Individual Inspection................................................................................................................... 6990
Heater Unit............................................................................................................................. 6992
Heater Unit and Associated Parts.................................................................................................... 6992
Removal............................................................................................................................. 6992
Installation........................................................................................................................ 6993
Heater Core and / or Mode Door.......................................................................................................... 6994
Disassembled View................................................................................................................... 6994
Removal............................................................................................................................. 6994
Inspection.......................................................................................................................... 6995
Installation........................................................................................................................ 6995
Heater Mode Control Link Unit........................................................................................................... 6996
Disassembled View................................................................................................................... 6996
Removal............................................................................................................................. 6996
Installation........................................................................................................................ 6997
Heater Temperature Control Link Unit.................................................................................................... 6997
Disassembled View................................................................................................................... 6997
Removal............................................................................................................................. 6997
Installation........................................................................................................................ 6997
Blower Assembly......................................................................................................................... 6998
Blower Assembly and Associated Parts................................................................................................ 6998
Removal............................................................................................................................. 6998
Installation........................................................................................................................ 6999
Blower Link Unit and / or Mode door..................................................................................................... 6999
Disassembled View................................................................................................................... 6999
Removal............................................................................................................................. 6999
Installation........................................................................................................................ 7000
Blower Motor............................................................................................................................ 7001
Blower Motor and Associated Parts................................................................................................... 7001
Removal............................................................................................................................. 7001
Installation........................................................................................................................ 7001
Rear Heater Duct, Defroster Nozzle and Ventilation Duct................................................................................. 7002
Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts........................................................... 7002
Removal............................................................................................................................. 7002
Installation........................................................................................................................ 7003
Center and / or Drive Side Vent......................................................................................................... 7003
Center Vent, Drive Side Vent and Associated Parts................................................................................... 7003
Removal............................................................................................................................. 7003
Installation........................................................................................................................ 7003
Control Lever Assembly and / or Control Cable........................................................................................... 7004
Control Lever Assembly, Control Cable and Associated Parts.......................................................................... 7004
Removal............................................................................................................................. 7004
Installation........................................................................................................................ 7005
Control Panel Illumination Bulb......................................................................................................... 7006
Control Panel Illumination Bulb and Associated Parts................................................................................ 7006
Removal............................................................................................................................. 7006
Installation........................................................................................................................ 7006
Resistor................................................................................................................................ 7007
Resistor and Associated Parts....................................................................................................... 7007
Removal............................................................................................................................. 7007
Installation........................................................................................................................ 7007
Air Conditioning System................................................................................................................. 7008
General Description..................................................................................................................... 7008
Diagnosis............................................................................................................................... 7017
Individual Inspection................................................................................................................... 7025
General Repair Procedure............................................................................................................ 7026
Compressor Assembly..................................................................................................................... 7033
Compressor Assembly and Associated Parts............................................................................................ 7033
Removal............................................................................................................................. 7033
Installation........................................................................................................................ 7034
Condenser Assembly...................................................................................................................... 7035
Condenser Assembly and Associated Parts............................................................................................. 7035
Removal............................................................................................................................. 7035
Installation........................................................................................................................ 7035
Receiver / Drier........................................................................................................................ 7036
Receiver / Drier and Associated Parts............................................................................................... 7036
Removal............................................................................................................................. 7036
Installation........................................................................................................................ 7036
Pressure Switch......................................................................................................................... 7037
Pressure Switch and Associated Parts................................................................................................ 7037
Removal............................................................................................................................. 7037
Installation........................................................................................................................ 7037
Evaporator Assembly..................................................................................................................... 7038
Evaporator Assembly and Associated Parts............................................................................................ 7038
Removal............................................................................................................................. 7038
Installation........................................................................................................................ 7039
Electronic Thermostat, Evaporator Core and/or Expansion Valve........................................................................... 7039
Disassembled View................................................................................................................... 7039
Removal............................................................................................................................. 7039
Installation........................................................................................................................ 7040
Air Conditioning Switch and Illumination Bulb........................................................................................... 7041
Air Conditioning Switch, Illumination Bulb and Associated Parts..................................................................... 7041
Removal............................................................................................................................. 7041
Installation........................................................................................................................ 7041
Refrigerant Line........................................................................................................................ 7042
Refrigerant Line and Associated Parts............................................................................................... 7042
Removal............................................................................................................................. 7042
Installation........................................................................................................................ 7043
Main Data And Specifications............................................................................................................ 7044
Compressor.............................................................................................................................. 7046
Service Precaution.................................................................................................................. 7046
General Description..................................................................................................................... 7046
Metric Thread Size Information...................................................................................................... 7048
Compressor Clutch Plate and Hub Assembly................................................................................................ 7048
Removal............................................................................................................................. 7048
Installation........................................................................................................................ 7048
Compressor Clutch Rotor and/or Bearing.................................................................................................. 7049
Removal............................................................................................................................. 7049
Installation........................................................................................................................ 7049
Compressor Clutch Coil.................................................................................................................. 7050
Removal............................................................................................................................. 7050
Installation........................................................................................................................ 7051
Compressor Shaft Seal................................................................................................................... 7052
Service Precaution...................................................................................................................... 7052
Seal Leak Detection................................................................................................................. 7052
Removal............................................................................................................................. 7052
Cleaning............................................................................................................................ 7053
Installation........................................................................................................................ 7053
Compressor Pressure Relief Valve........................................................................................................ 7054
Removal............................................................................................................................. 7054
Installation........................................................................................................................ 7054
Compressor Oil.......................................................................................................................... 7054
Compressor Oil Check................................................................................................................ 7054
Checking and Adjusting Oil Quantity for Used Compressor............................................................................. 7054
Checking and Adjusting for Compressor Replacement................................................................................... 7054
Contamination of Compressor Oil..................................................................................................... 7055
Oil Return Operation................................................................................................................ 7055
Replacement of Component Parts...................................................................................................... 7055
Compressor Leak Testing (External and Internal)..................................................................................... 7055
Special Tools........................................................................................................................... 7057
Automatic Air Conditioning System....................................................................................................... 7059
General Description..................................................................................................................... 7059
Full Automatic Air Conditioner Parts Configuration.................................................................................. 7059
Refrigerant Line and Associated Parts............................................................................................... 7060
Circuit Diagram......................................................................................................................... 7061
Functions and Features.................................................................................................................. 7066
Automatic Air Conditioner Block Diagram................................................................................................. 7067
Control Panel Layout.................................................................................................................... 7068
Air Control Functions................................................................................................................... 7069
Operation and Functions of Control Panel Switches....................................................................................... 7070
Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System....................................... 7072
Overview of Automatic Control of Automatic Air Conditioner.............................................................................. 7076
Troubleshooting......................................................................................................................... 7080
Troubleshooting, Its Overview and Procedures........................................................................................ 7080
Auto Air Conditioner Control Unit Power Supply Diagnosis............................................................................ 7081
Performance and Movement checklist for Automatic Air Conditioner Related Parts...................................................... 7083
Troubleshooting With Self-Diagnosis Function........................................................................................ 7085
Inspection By Failed Location........................................................................................................... 7089
Inspection of the Sensors........................................................................................................... 7089
Inspection of the Intake Actuator System............................................................................................ 7093
Inspection of the Mix Actuator System............................................................................................... 7096
Inspection of the Mode Actuator System.............................................................................................. 7099
Inspection of the Fan Motor System.................................................................................................. 7102
Inspection of the Magnetic Clutch System............................................................................................ 7107
Individual Inspection............................................................................................................... 7110
On-Vehicle Service...................................................................................................................... 7113
Power Transistor.................................................................................................................... 7113
Removal......................................................................................................................... 7113
Installation.................................................................................................................... 7113
Automatic Heater/Air Conditioner Control Unit....................................................................................... 7113
Removal......................................................................................................................... 7113
Installation.................................................................................................................... 7113
In Car Sensor....................................................................................................................... 7114
Removal......................................................................................................................... 7114
Installation.................................................................................................................... 7114
Ambient Sensor...................................................................................................................... 7114
Removal......................................................................................................................... 7114
Installation.................................................................................................................... 7114
Sun Sensor.......................................................................................................................... 7115
Removal......................................................................................................................... 7115
Installation.................................................................................................................... 7115
Electronic Thermostat............................................................................................................... 7115
Removal......................................................................................................................... 7115
Installation.................................................................................................................... 7115
Mode Actuator....................................................................................................................... 7116
Removal......................................................................................................................... 7116
Installation.................................................................................................................... 7116
Mix Actuator........................................................................................................................ 7116
Removal......................................................................................................................... 7116
Installation.................................................................................................................... 7116
Intake Actuator..................................................................................................................... 7117
Removal......................................................................................................................... 7117
Installation.................................................................................................................... 7117
Sec.2 STEERING................................................................................................................................ 7118
2A POWER ASSISTED SYSTEM................................................................................................................... 7118
Service Precaution...................................................................................................................... 7119
General Description..................................................................................................................... 7119
Diagnosis............................................................................................................................... 7122
Power Steering System Test.............................................................................................................. 7128
Maintenance............................................................................................................................. 7129
Fluid Level............................................................................................................................. 7129
Bleeding The Power Steering System...................................................................................................... 7129
Bleeding Procedure...................................................................................................................... 7129
Flushing The Power Steering System...................................................................................................... 7129
Steering Wheel Free Play Adjustment..................................................................................................... 7130
Front End Alignment Inspection and Adjustment........................................................................................... 7130
Main Data and Specifications............................................................................................................ 7135
Special Tools........................................................................................................................... 7136
Power Steering Gear..................................................................................................................... 7137
Power Steering Gear and Associated Parts............................................................................................ 7137
Removal............................................................................................................................. 7137
Installation........................................................................................................................ 7138
Steering Gear Disassembled View..................................................................................................... 7139
Disassembly......................................................................................................................... 7140
Inspection and Repair............................................................................................................... 7141
Reassembly.......................................................................................................................... 7142
Main Data and Specifications........................................................................................................ 7144
Power Steering Pump..................................................................................................................... 7145
Power Steering Pump and Associated Parts............................................................................................ 7145
Removal............................................................................................................................. 7145
Installation........................................................................................................................ 7146
Power Steering Pump Disassembled View............................................................................................... 7147
Disassembly......................................................................................................................... 7147
Inspection and Repair............................................................................................................... 7148
Reassembly.......................................................................................................................... 7149
Main Data and Specifications........................................................................................................ 7150
Center Track Rod Assembly............................................................................................................... 7151
Center Track Rod Assembly and Associated Parts...................................................................................... 7151
Removal............................................................................................................................. 7152
Inspection and Repair............................................................................................................... 7152
Installation........................................................................................................................ 7152
Outer Track Rod Assembly................................................................................................................ 7153
Outer Track Rod Assembly and Associated Parts....................................................................................... 7153
Removal............................................................................................................................. 7154
Inspection and Repair............................................................................................................... 7154
Installation........................................................................................................................ 7155
Relay Lever............................................................................................................................. 7156
Relay Lever and Associated Parts.................................................................................................... 7156
Removal............................................................................................................................. 7156
Installation........................................................................................................................ 7157
Steering Linkage and Associated Parts................................................................................................... 7158
Main Data and Specifications........................................................................................................ 7158
Special Tools....................................................................................................................... 7159
Supplemental Restraint System Steering Wheel & Column................................................................................... 7160
Service Precaution.................................................................................................................. 7160
SRS Connectors...................................................................................................................... 7160
Inflator Module......................................................................................................................... 7162
Inflator Module and Associated Parts................................................................................................ 7162
Removal............................................................................................................................. 7162
Inspection and Repair............................................................................................................... 7163
Installation........................................................................................................................ 7163
Steering Wheel.......................................................................................................................... 7164
Steering Wheel and Associated Parts................................................................................................. 7164
Removal............................................................................................................................. 7164
Installation........................................................................................................................ 7166
Combination Switch...................................................................................................................... 7167
Combination Switch and Associated Parts............................................................................................. 7167
Removal............................................................................................................................. 7167
Installation........................................................................................................................ 7169
Lock Cylinder........................................................................................................................... 7171
Lock Cylinder and Associated Parts.................................................................................................. 7171
Removal............................................................................................................................. 7171
Installation........................................................................................................................ 7173
System Inspection................................................................................................................... 7174
Steering Column......................................................................................................................... 7175
Steering Column and Associated Parts................................................................................................ 7175
Removal............................................................................................................................. 7175
Inspection.......................................................................................................................... 7177
Installation........................................................................................................................ 7179
System Inspection................................................................................................................... 7180
Supplemental Restraint System Steering Wheel & Column and Associated Parts.............................................................. 7181
Main Data and Specifications........................................................................................................ 7181
Special Tools....................................................................................................................... 7182
Sec.3 SUSPENSION.............................................................................................................................. 7183
3C FRONT SUSPENSION....................................................................................................................... 7183
Service Precaution...................................................................................................................... 7183
General Description..................................................................................................................... 7184
General Diagnosis....................................................................................................................... 7185
Shock Absorber.......................................................................................................................... 7188
Shock Absorber and Associated Parts................................................................................................. 7188
Removal............................................................................................................................. 7188
Inspection and Repair............................................................................................................... 7188
Installation........................................................................................................................ 7188
Stabilizer Bar.......................................................................................................................... 7189
Stabilizer Bar and Associated Parts................................................................................................. 7189
Removal............................................................................................................................. 7189
Inspection and Repair............................................................................................................... 7189
Installation........................................................................................................................ 7189
Torsion Bar............................................................................................................................. 7190
Torsion Bar and Associated Parts.................................................................................................... 7190
Removal............................................................................................................................. 7190
Inspection and Repair............................................................................................................... 7191
Installation........................................................................................................................ 7191
Knuckle................................................................................................................................. 7193
Knuckle and Associated Parts........................................................................................................ 7193
Removal............................................................................................................................. 7193
Inspection and Repair............................................................................................................... 7194
Installation........................................................................................................................ 7194
Upper Control Arm....................................................................................................................... 7196
Upper Control Arm and Associated Parts.............................................................................................. 7196
Removal............................................................................................................................. 7196
Inspection and Repair............................................................................................................... 7197
Installation........................................................................................................................ 7198
Lower Control Arm....................................................................................................................... 7200
Lower Control Arm and Associated Parts.............................................................................................. 7200
Removal............................................................................................................................. 7200
Inspection and Repair............................................................................................................... 7202
Installation........................................................................................................................ 7202
Upper Ball Joint........................................................................................................................ 7204
Upper Ball Joint and Associated Parts............................................................................................... 7204
Removal............................................................................................................................. 7204
Inspection and Repair............................................................................................................... 7205
Installation........................................................................................................................ 7205
Lower Ball Joint........................................................................................................................ 7206
Lower Ball Joint and Associated Parts............................................................................................... 7206
Removal............................................................................................................................. 7206
Inspection and Repair............................................................................................................... 7207
Installation........................................................................................................................ 7207
Main Data and Specifications............................................................................................................ 7208
Special Tools........................................................................................................................... 7209
3D REAR SUSPENSION........................................................................................................................ 7210
Service Precaution...................................................................................................................... 7210
General Description..................................................................................................................... 7211
Coil Spring............................................................................................................................. 7212
Coil Spring and Associated Parts.................................................................................................... 7212
Removal............................................................................................................................. 7212
Inspection and Repair............................................................................................................... 7213
Installation........................................................................................................................ 7213
Shock Absorber.......................................................................................................................... 7214
Shock Absorber and Associated Parts................................................................................................. 7214
Removal............................................................................................................................. 7214
Inspection and Repair............................................................................................................... 7214
Installation........................................................................................................................ 7214
Trailing Link........................................................................................................................... 7215
Trailing Link and Associated Parts.................................................................................................. 7215
Removal............................................................................................................................. 7215
Inspection and Repair............................................................................................................... 7215
Installation........................................................................................................................ 7216
Center Link............................................................................................................................. 7217
Center Link and Associated Parts.................................................................................................... 7217
Removal............................................................................................................................. 7217
Inspection and Repair............................................................................................................... 7217
Installation........................................................................................................................ 7218
Lateral Rod............................................................................................................................. 7219
Lateral Rod and Associated Parts.................................................................................................... 7219
Removal............................................................................................................................. 7219
Inspection and Repair............................................................................................................... 7219
Installation........................................................................................................................ 7220
Stabilizer Bar.......................................................................................................................... 7221
Stabilizer Bar and Associated Parts................................................................................................. 7221
Removal............................................................................................................................. 7221
Inspection and Repair............................................................................................................... 7221
Installation........................................................................................................................ 7222
Main Data and Specifications............................................................................................................ 7223
Special Tools........................................................................................................................... 7225
3E WHEEL AND TIRE SYSTEM.................................................................................................................. 7226
Service Precaution...................................................................................................................... 7226
General Description..................................................................................................................... 7227
Diagnosis............................................................................................................................... 7228
Wheel................................................................................................................................... 7234
Wheel and Associated Parts.......................................................................................................... 7234
Removal............................................................................................................................. 7234
Installation........................................................................................................................ 7234
Tire.................................................................................................................................... 7235
Tire Replacement.................................................................................................................... 7235
General Balance Procedure............................................................................................................... 7235
Balancing Wheel and Tire................................................................................................................ 7236
Main Data and Specifications............................................................................................................ 7237
Sec.4 DRIVELINE/AXLE.......................................................................................................................... 7238
4A1 DIFFERENTIAL (FRONT).................................................................................................................. 7238
Service Precaution...................................................................................................................... 7238
Front Drive Axle........................................................................................................................ 7239
Diagnosis............................................................................................................................... 7239
Pinion Shaft Oil Seal................................................................................................................... 7240
Pinion Shaft Oil Seal and Associated Parts.......................................................................................... 7240
Removal............................................................................................................................. 7240
Inspection and Repair............................................................................................................... 7241
Installation........................................................................................................................ 7241
Front Drive Axle Assembly............................................................................................................... 7242
Front Drive Axle Assembly and Associated Parts...................................................................................... 7242
Removal............................................................................................................................. 7242
Installation........................................................................................................................ 7244
Differential Assembly................................................................................................................... 7246
Disassembled View................................................................................................................... 7246
Disassembly......................................................................................................................... 7246
Reassembly.......................................................................................................................... 7249
Differential Cage Assembly.............................................................................................................. 7258
Disassembled View................................................................................................................... 7258
Disassembly......................................................................................................................... 7258
Inspection and Repair............................................................................................................... 7259
Reassembly.......................................................................................................................... 7260
Main Data and Specifications............................................................................................................ 7262
Special Tools........................................................................................................................... 7264
4A2 DIFFERENTIAL (REAR)................................................................................................................... 7266
Service Precaution...................................................................................................................... 7266
General Description..................................................................................................................... 7268
Diagnosis............................................................................................................................... 7269
Axle Housing............................................................................................................................ 7270
Axle Housing and Associated Parts................................................................................................... 7270
Removal............................................................................................................................. 7270
Oil Seal Replacement................................................................................................................ 7271
Installation........................................................................................................................ 7271
Axle Shaft.............................................................................................................................. 7272
Axle Shaft and Associated Parts..................................................................................................... 7272
Removal............................................................................................................................. 7272
Inspection and Repair............................................................................................................... 7273
Oil Seal Replacement................................................................................................................ 7274
Installation........................................................................................................................ 7274
Pinion Oil Seal......................................................................................................................... 7275
Pinion Oil Seal and Associated Parts................................................................................................ 7275
Removal............................................................................................................................. 7275
Inspection and Repair............................................................................................................... 7276
Installation........................................................................................................................ 7276
Differential Assembly................................................................................................................... 7277
Differential Assembly and Associated Parts.......................................................................................... 7277
Removal............................................................................................................................. 7277
Installation........................................................................................................................ 7278
Disassembled View................................................................................................................... 7279
Disassembly......................................................................................................................... 7280
Reassembly.......................................................................................................................... 7282
Differential Cage Assembly.............................................................................................................. 7289
Disassembled View................................................................................................................... 7289
Disassembly......................................................................................................................... 7290
Inspection and Repair............................................................................................................... 7290
Reassembly.......................................................................................................................... 7291
Limited Slip Differential............................................................................................................... 7293
Disassembled View................................................................................................................... 7293
Disassembly......................................................................................................................... 7294
Inspection and Repair............................................................................................................... 7294
Reassembly.......................................................................................................................... 7296
Main Data and Specifications............................................................................................................ 7300
Special Tools........................................................................................................................... 7301
4B1 DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)........................................................................................... 7304
Service Precaution...................................................................................................................... 7304
Shift On The Fly System................................................................................................................. 7305
Outline of Shift on The Fly System...................................................................................................... 7305
Functions of Indicator Lamp............................................................................................................. 7309
Diagnosis............................................................................................................................... 7310
Front Axle Diagnosis.................................................................................................................... 7320
Shift On The Fly Vacuum Piping And Electric Equipment................................................................................... 7322
Vacuum piping diagram................................................................................................................... 7322
Inspection And Repair................................................................................................................... 7323
4WD Control Unit........................................................................................................................ 7326
4WD Control Unit Associated Parts................................................................................................... 7326
Removal............................................................................................................................. 7327
Installation........................................................................................................................ 7327
4B2 DRIVELINE CONTROL SYSTEM (TOD)........................................................................................................ 7328
Service Precaution...................................................................................................................... 7328
General Description..................................................................................................................... 7329
System Components....................................................................................................................... 7331
Parts Location...................................................................................................................... 7331
Functions of Indicator Lamp............................................................................................................. 7335
Diagnosis............................................................................................................................... 7338
Basic Diagnostic Flow Chart............................................................................................................. 7342
Parts Location.......................................................................................................................... 7343
Circuit Diagram......................................................................................................................... 7344
Connector List.......................................................................................................................... 7347
Checking Failed Pin..................................................................................................................... 7349
Checking Failed TOD Control Unit Pin.................................................................................................... 7352
Tech 2 Scan Tool.................................................................................................................... 7353
Diagnostic Trouble Codes................................................................................................................ 7356
Diagnosis from Trouble Codes............................................................................................................ 7357
Trouble Diagnosis Depending on The Status of TOD Indicator.............................................................................. 7381
Diagnosis from Symptom.................................................................................................................. 7410
4C DRIVE SHAFT SYSTEM .................................................................................................................. 7420
Service Precaution...................................................................................................................... 7421
General Description..................................................................................................................... 7421
Diagnosis............................................................................................................................... 7422
Front Hub and Disc (2WD Model).......................................................................................................... 7423
Disassembled View................................................................................................................... 7423
Disassembly......................................................................................................................... 7423
Inspection and Repair............................................................................................................... 7425
Reassembly.......................................................................................................................... 7425
Main Data and Specifications........................................................................................................ 7428
Special Tools....................................................................................................................... 7429
Front Hub and Disc (4WD Model).......................................................................................................... 7430
Disassembled View................................................................................................................... 7430
Disassembly......................................................................................................................... 7430
Inspection and Repair............................................................................................................... 7431
Reassembly.......................................................................................................................... 7431
Main Data and Specifications........................................................................................................ 7435
Special Tools....................................................................................................................... 7436
Front Drive Shaft Joint................................................................................................................. 7437
Front Drive Shaft Joints Replace-ment............................................................................................... 7437
Front Axle Drive Shaft.................................................................................................................. 7438
Front Axle Drive Shaft and Associated Parts......................................................................................... 7438
Disassembly......................................................................................................................... 7439
Inspection and Repair............................................................................................................... 7440
Bushing Replacement................................................................................................................. 7440
Reassembly.......................................................................................................................... 7441
Shift On The Fly System................................................................................................................. 7443
Shift On The Fly System and Associated Parts........................................................................................ 7443
Disassembly......................................................................................................................... 7443
Inspection and Repair............................................................................................................... 7445
Main Data and Specifications........................................................................................................ 7450
Special Tools....................................................................................................................... 7451
Front Propeller Shaft................................................................................................................... 7452
General Description................................................................................................................. 7452
Front Propeller Shaft and Associated Parts.......................................................................................... 7453
Removal............................................................................................................................. 7453
Installation........................................................................................................................ 7454
Disassembly (Except TOD 4×4)........................................................................................................ 7455
Universal Joint Disassembly......................................................................................................... 7456
Inspection and Repair............................................................................................................... 7457
Universal Joint Reassembly.......................................................................................................... 7460
Reassembly (Except TOD 4ﾗ4)......................................................................................................... 7461
Main Data and Specifications........................................................................................................ 7462
Rear Propeller Shaft.................................................................................................................... 7463
General Description................................................................................................................. 7463
Rear Propeller Shaft and Associated Parts........................................................................................... 7463
Removal............................................................................................................................. 7463
Installation........................................................................................................................ 7464
Disassembly......................................................................................................................... 7465
Universal Joint Disassembly......................................................................................................... 7466
Inspection and Repair............................................................................................................... 7467
Universal Joint Reassembly.......................................................................................................... 7468
Reassembly.......................................................................................................................... 7469
Main Data and Specifications........................................................................................................ 7470
4D1 TRANSFER CASE (STANDARD TYPE)......................................................................................................... 7471
Service Precaution...................................................................................................................... 7471
General Description..................................................................................................................... 7472
Transfer Rear Oil Seal.................................................................................................................. 7474
Removal............................................................................................................................. 7474
Installation........................................................................................................................ 7474
Transfer Case Assembly.................................................................................................................. 7475
Removal............................................................................................................................. 7475
Installation........................................................................................................................ 7475
Transfer Rear Case Assembly............................................................................................................. 7477
Removal............................................................................................................................. 7477
Installation........................................................................................................................ 7478
Disassembly......................................................................................................................... 7481
Inspection and Repair............................................................................................................... 7482
Reassembly.......................................................................................................................... 7482
Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)........................................................................... 7484
Disassembled View................................................................................................................... 7484
Disassembly......................................................................................................................... 7484
Inspection and Repair............................................................................................................... 7486
Reassembly.......................................................................................................................... 7486
Transfer Case Assembly.................................................................................................................. 7488
Disassembled View................................................................................................................... 7488
Disassembly......................................................................................................................... 7489
Inspection and Repair............................................................................................................... 7491
Reassembly.......................................................................................................................... 7495
Main Data and Specifications............................................................................................................ 7501
Special Tools........................................................................................................................... 7504
4D2 TRANSFER CASE (TOD)................................................................................................................... 7506
Service Precaution...................................................................................................................... 7506
Transfer Case Assembly.................................................................................................................. 7507
Removal............................................................................................................................. 7507
Installation........................................................................................................................ 7508
Transfer Rear Oil Seal.................................................................................................................. 7510
Transfer Rear Oil Seal and Associated Parts......................................................................................... 7510
Removal............................................................................................................................. 7510
Installation........................................................................................................................ 7510
TOD ECU................................................................................................................................. 7512
Removal............................................................................................................................. 7512
Installation........................................................................................................................ 7512
Unit Repair............................................................................................................................. 7513
Inspection.......................................................................................................................... 7513
Transfer Case........................................................................................................................... 7514
Disassembled View................................................................................................................... 7514
Disassembly......................................................................................................................... 7514
Reassembly.......................................................................................................................... 7515
Transfer Cover Assembly................................................................................................................. 7517
Disassembled View................................................................................................................... 7517
Disassembly......................................................................................................................... 7517
Reassembly.......................................................................................................................... 7519
Transfer Case Assembly Clutch Pack and Clutch Cam....................................................................................... 7521
Disassembled View................................................................................................................... 7521
Disassembly......................................................................................................................... 7521
Sprocket and Mechanical Lock............................................................................................................ 7523
Disassembled View................................................................................................................... 7523
Disassembly......................................................................................................................... 7523
Output Shafts and Shift Control Shaft................................................................................................... 7525
Disassembled View................................................................................................................... 7525
Disassembly......................................................................................................................... 7526
Transfer Case........................................................................................................................... 7528
Disassembled View................................................................................................................... 7528
Disassembly......................................................................................................................... 7529
Inspection and Repair............................................................................................................... 7531
Transfer Case........................................................................................................................... 7535
Disassembled View................................................................................................................... 7535
Reassembly.......................................................................................................................... 7535
Output Shafts and Shift Control Shaft................................................................................................... 7538
Disassembled View................................................................................................................... 7538
Reassembly.......................................................................................................................... 7538
Sprocket and Mechanical Lock............................................................................................................ 7541
Disassembled View................................................................................................................... 7541
Reassembly.......................................................................................................................... 7541
Clutch Pack and Clutch Cam.............................................................................................................. 7543
Disassembled View................................................................................................................... 7543
Reassembly.......................................................................................................................... 7543
Main Data and Specifications............................................................................................................ 7545
Special Tools........................................................................................................................... 7547
Sec.5 BRAKES.................................................................................................................................. 7600
5A BRAKE CONTROL SYSTEM................................................................................................................... 7548
Service Precaution...................................................................................................................... 7549
General Description..................................................................................................................... 7550
System Components................................................................................................................... 7550
Electronic Hydraulic Control Unit (EHCU)............................................................................................ 7550
ABS Warning Light................................................................................................................... 7551
Wheel Speed Sensor.................................................................................................................. 7551
G-Sensor............................................................................................................................ 7551
Normal and Anti-lock Braking........................................................................................................ 7551
Brake Pedal Travel.................................................................................................................. 7551
Acronyms and Abbreviations.......................................................................................................... 7551
General Diagnosis....................................................................................................................... 7552
General Information................................................................................................................. 7552
ABS Service Precautions............................................................................................................. 7552
Computer System Service Precautions................................................................................................. 7552
General Service Precautions......................................................................................................... 7552
Note on Intermittents............................................................................................................... 7552
Test Driving ABS Complaint Vehicles................................................................................................. 7552
"ABS" Warning Light................................................................................................................. 7553
Normal Operation.................................................................................................................... 7553
Basic Diagnostic Flow Chart......................................................................................................... 7553
Basic Inspection Procedure.......................................................................................................... 7554
Tech 2 Scan Tool.................................................................................................................... 7555
Getting Started..................................................................................................................... 7556
Operating Procedure................................................................................................................. 7556
Data List............................................................................................................................... 7558
EHCU Connector Pin-out Checks........................................................................................................... 7559
Circuit Diagram..................................................................................................................... 7560
Connector List...................................................................................................................... 7563
Part Location....................................................................................................................... 7565
Symptom Diagnosis....................................................................................................................... 7566
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate...................................................................... 7566
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................ 7567
Chart A-2 Uneven Braking Occurs While ABS Works..................................................................................... 7567
Chart A-3, TA-3 The Wheels Are Locked............................................................................................... 7568
Chart A-4 Brake Pedal Feed Is Abnormal.............................................................................................. 7568
Chart A-5,TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................. 7569
Diagnostic Trouble Codes................................................................................................................ 7570
Diagnosis By "ABS" Warning Light Illumination Pattern............................................................................... 7571
Diagnostic Trouble Codes (DTCs)..................................................................................................... 7571
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................ 7574
Chart B-2 EHCU Abnormality (DTC 14)................................................................................................. 7574
Chart B-3 Power Voltage Drop (DTC 15)............................................................................................... 7575
Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)........................................................................... 7575
Chart B-5 G-Sensor Circuit (DTC 21)................................................................................................. 7575
Chart B-6 Abnormal Transmission Input (DTC 23)...................................................................................... 7576
Chart B-7 Transfer Monitor (DTC 24)................................................................................................. 7577
Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32).......................................................................... 7577
Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35).......................................................................... 7578
Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41)......................................................................... 7578
Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42).............................................................................. 7578
Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43)......................................................................... 7579
Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44).............................................................................. 7579
Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45)....................................................................... 7579
Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)............................................................................ 7580
Chart B-16 FL Speed Sensor Disconnection (DTC 51)................................................................................... 7580
Chart B-17 FR Speed Sensor Disconnection (DTC 52)................................................................................... 7581
Chart B-18 RL Speed Sensor Disconnection (DTC 53)................................................................................... 7581
Chart B-19 RR Speed Sensor Disconnection (DTC 54)................................................................................... 7582
Chart B-20 FL Speed Sensor Short Circuit (DTC 61)................................................................................... 7583
Chart B-21 FR Speed Sensor Short Circuit (DTC 62)................................................................................... 7584
Chart B-22 RL Speed Sensor Short Circuit (DTC 63)................................................................................... 7585
Chart B-23 RR Speed Sensor Short Circuit (DTC 64)................................................................................... 7586
Chart B-24 Sensor Signal Input Abnormality (DTC 65)................................................................................. 7587
Sensor Signal Abnormality Criteria using TECH 2..................................................................................... 7587
Unit Inspection Procedure............................................................................................................... 7588
Chart C-1-1 FL Sensor Output Inspection Procedure................................................................................... 7588
Chart C-1-2 FR Sensor Output Inspection Procedure................................................................................... 7589
Chart C-1-3 RL Sensor Output Inspection Procedure................................................................................... 7589
Chart C-1-4 RR Sensor Output Inspection Procedure................................................................................... 7590
Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2).......................................................................... 7590
Chart C-2 Transmission Input Inspection Procedure................................................................................... 7591
Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2)..................................................................... 7592
Special Tools........................................................................................................................... 7593
5B ANTI-LOCK BRAKE SYSTEM................................................................................................................. 7594
Service Precaution...................................................................................................................... 7594
Electronic Hydraulic Control Unit....................................................................................................... 7595
Electronic Hydraulic Control Unit and Associated Parts.............................................................................. 7595
Removal............................................................................................................................. 7595
Installation........................................................................................................................ 7595
G-Sensor................................................................................................................................ 7596
Removal............................................................................................................................. 7596
Inspection and Repair............................................................................................................... 7596
Installation........................................................................................................................ 7596
Front Wheel Speed Sensor................................................................................................................ 7597
Front Wheel Speed Sensor and Associated Parts....................................................................................... 7597
Removal............................................................................................................................. 7597
Inspection and Repair............................................................................................................... 7598
Installation........................................................................................................................ 7598
Rear Wheel Speed Sensor................................................................................................................. 7599
Rear Wheel Speed Sensor and Associated Parts........................................................................................ 7599
Removal............................................................................................................................. 7599
Inspection and Repair............................................................................................................... 7599
Installation........................................................................................................................ 7599
5C POWER-ASSISTED BRAKE SYSTEM............................................................................................................ 7600
Service Precaution...................................................................................................................... 7601
General Description..................................................................................................................... 7601
Diagnosis............................................................................................................................... 7604
General Diagnosis....................................................................................................................... 7605
Hydraulic Brakes........................................................................................................................ 7608
Filling Master Cylinder Reservoir................................................................................................... 7608
Deterioration of Brake Fluid........................................................................................................ 7608
Leakage of Brake Fluid.............................................................................................................. 7608
Bleeding Brake Hydraulic System..................................................................................................... 7608
Flushing Brake Hydraulic System..................................................................................................... 7609
Brake Pipes and Hoses............................................................................................................... 7609
Brake Hose Inspection............................................................................................................... 7609
Front / Rear Caliper Brake Hose......................................................................................................... 7610
Front / Rear Caliper Brake Hose and Associated Parts................................................................................ 7610
Removal............................................................................................................................. 7610
Installation........................................................................................................................ 7610
Rear Axle Brake Hose.................................................................................................................... 7611
Rear Axle Brake Hose and Associated Parts........................................................................................... 7611
Removal............................................................................................................................. 7611
Installation........................................................................................................................ 7611
Brake Pipe.............................................................................................................................. 7612
Removal............................................................................................................................. 7612
Installation........................................................................................................................ 7612
P & B (Proportioning and Bypass) Valve.................................................................................................. 7613
P & B (Proportioning and Bypass) Valve Sectional View............................................................................... 7613
Removal............................................................................................................................. 7613
Installation........................................................................................................................ 7613
Main Data and Specifications........................................................................................................ 7614
Brake Pedal............................................................................................................................. 7615
Checking Pedal Height............................................................................................................... 7615
Checking Pedal Travel............................................................................................................... 7615
Brake Pedal and Associated Parts.................................................................................................... 7616
Removal............................................................................................................................. 7616
Installation........................................................................................................................ 7616
Stoplight Switch........................................................................................................................ 7617
Removal............................................................................................................................. 7617
Installation........................................................................................................................ 7617
Main Data and Specifications........................................................................................................ 7618
Fluid Reservoir Tank.................................................................................................................... 7619
Fluid Reservoir Tank and Associated Parts........................................................................................... 7619
Removal............................................................................................................................. 7619
Installation........................................................................................................................ 7619
Master Cylinder Assembly................................................................................................................ 7620
Master Cylinder Assembly and Associated Parts....................................................................................... 7620
Removal............................................................................................................................. 7620
Inspection and Repair............................................................................................................... 7620
Installation........................................................................................................................ 7621
Main Data and Specifications........................................................................................................ 7622
Special Tools....................................................................................................................... 7623
Vacuum Booster Assembly................................................................................................................. 7624
Vacuum Booster Assembly and Associated Parts........................................................................................ 7624
Removal............................................................................................................................. 7624
Inspection and Repair............................................................................................................... 7624
Installation........................................................................................................................ 7625
Exterior Components..................................................................................................................... 7627
Exterior Components and Associated Parts............................................................................................ 7627
Removal............................................................................................................................. 7627
Inspection and Repair............................................................................................................... 7628
Installation........................................................................................................................ 7628
Vacuum Booster Overhaul................................................................................................................. 7628
Vacuum Booster...................................................................................................................... 7628
Main Data and Specifications........................................................................................................ 7629
Special Tools....................................................................................................................... 7630
Front Disc Brake Pads................................................................................................................... 7631
Front Disc Brake Pads Inspection.................................................................................................... 7631
Front Disc Brake Pads and Associated Parts.......................................................................................... 7631
Removal............................................................................................................................. 7632
Installation........................................................................................................................ 7632
Front Disc Brake Rotor.................................................................................................................. 7634
Inspection.......................................................................................................................... 7634
Replacing Brake Rotors.............................................................................................................. 7634
Refinishing Brake Rotors............................................................................................................ 7634
Front Disc Brake Caliper Assembly....................................................................................................... 7636
Front Disc Brake Caliper Assembly and Associated Parts.............................................................................. 7636
Removal............................................................................................................................. 7636
Installation........................................................................................................................ 7637
Front Disc Brake Caliper................................................................................................................ 7639
Front Disc Brake Caliper Disassembled View.......................................................................................... 7639
Disassembly......................................................................................................................... 7639
Inspection and Repair............................................................................................................... 7640
Reassembly.......................................................................................................................... 7640
Main Data and Specifications........................................................................................................ 7642
Rear Disc Brake Pads.................................................................................................................... 7643
Brake Pads Inspection............................................................................................................... 7643
Brake Pads and Associated Parts..................................................................................................... 7643
Removal............................................................................................................................. 7644
Installation........................................................................................................................ 7644
Rear Disc Brake Rotor................................................................................................................... 7646
Inspection.......................................................................................................................... 7646
Replacing Brake Rotors.............................................................................................................. 7646
Refinishing Brake Rotors............................................................................................................ 7646
Rear Drum (In Disc) Inside Diameter Check........................................................................................... 7647
Rear Disc Brake Caliper Assembly........................................................................................................ 7648
Rear Disc Brake Caliper Assembly and Associated Parts............................................................................... 7648
Removal............................................................................................................................. 7648
Installation........................................................................................................................ 7649
Rear Disc Brake Caliper................................................................................................................. 7651
Rear Disc Brake Caliper Disassembled View........................................................................................... 7651
Disassembly......................................................................................................................... 7651
Inspection and Repair............................................................................................................... 7652
Reassembly.......................................................................................................................... 7652
Main Data and Specifications........................................................................................................ 7654
5D PARKING BRAKE SYSTEM................................................................................................................... 7655
Service Precaution...................................................................................................................... 7655
General Description..................................................................................................................... 7655
Operation............................................................................................................................... 7656
Parking Brake Lever and Front Cable..................................................................................................... 7657
Parking Brake Lever, Front Cable and Associated Parts............................................................................... 7657
Removal............................................................................................................................. 7657
Installation........................................................................................................................ 7658
Parking Brake Rear Cable................................................................................................................ 7659
Parking Brake Rear Cable and Associated Parts....................................................................................... 7659
Removal............................................................................................................................. 7659
Installation........................................................................................................................ 7660
Inspection and Repair............................................................................................................... 7661
Parking Brake Adjustment................................................................................................................ 7661
Main Data and Specifications............................................................................................................ 7662
Sec.6 ENGINE.................................................................................................................................. 7663
6A ENGINE MECHANICAL..................................................................................................................... 7663
Service Precaution...................................................................................................................... 7664
General Description..................................................................................................................... 7665
Engine Diagnosis........................................................................................................................ 7666
Cylinder Head Cover LH.................................................................................................................. 7681
Removal............................................................................................................................. 7681
Installation........................................................................................................................ 7682
Cylinder Head Cover RH.................................................................................................................. 7683
Removal............................................................................................................................. 7683
Installation........................................................................................................................ 7683
Common Chamber.......................................................................................................................... 7684
Removal............................................................................................................................. 7684
Installation........................................................................................................................ 7684
Exhaust Manifold LH..................................................................................................................... 7686
Removal............................................................................................................................. 7686
Installation........................................................................................................................ 7686
Exhaust Manifold RH..................................................................................................................... 7687
Removal............................................................................................................................. 7687
Installation........................................................................................................................ 7687
Crankshaft Pulley....................................................................................................................... 7688
Removal............................................................................................................................. 7688
Installation........................................................................................................................ 7688
Timing Belt............................................................................................................................. 7689
Removal............................................................................................................................. 7689
Installation........................................................................................................................ 7690
Camshaft................................................................................................................................ 7694
Removal............................................................................................................................. 7694
Installation........................................................................................................................ 7694
Cylinder Head........................................................................................................................... 7697
Removal............................................................................................................................. 7697
Installation........................................................................................................................ 7697
Valve Stem Oil Controller , Valve Spring and Valve Guide................................................................................ 7699
Removal............................................................................................................................. 7699
Installation........................................................................................................................ 7699
Piston, Piston Ring and Connecting Rod.................................................................................................. 7700
Removal............................................................................................................................. 7700
Installation........................................................................................................................ 7701
Crankshaft and Main Bearings............................................................................................................ 7702
Removal............................................................................................................................. 7702
Installation........................................................................................................................ 7703
Rear Oil Seal........................................................................................................................... 7707
Removal............................................................................................................................. 7707
Installation........................................................................................................................ 7707
Engine Assembly......................................................................................................................... 7708
Removal............................................................................................................................. 7708
Installation........................................................................................................................ 7709
Cylinder Head........................................................................................................................... 7711
Cylinder Head and Associated Parts.................................................................................................. 7711
Disassembly......................................................................................................................... 7712
Clean............................................................................................................................... 7712
Inspection and Repair............................................................................................................... 7712
Reassembly.......................................................................................................................... 7713
Valve Spring, Oil Controller, Valve, Valve Guide........................................................................................ 7715
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts............................................................... 7715
Disassembly......................................................................................................................... 7715
Inspection and Repair............................................................................................................... 7716
Reassembly.......................................................................................................................... 7719
Valve Clearance Adjustments......................................................................................................... 7720
Camshaft................................................................................................................................ 7722
Camshaft and Associated Parts....................................................................................................... 7722
Disassembly......................................................................................................................... 7722
Inspection and Repair............................................................................................................... 7723
Reassembly.......................................................................................................................... 7725
Crankshaft.............................................................................................................................. 7728
Crankshaft and Associated Parts..................................................................................................... 7728
Disassembly......................................................................................................................... 7729
Inspection and Repair............................................................................................................... 7729
Inspection and Repair............................................................................................................... 7730
Reassembly.......................................................................................................................... 7732
Piston and Connecting Rod............................................................................................................... 7736
Piston, Connecting Rod and Associate Parts.......................................................................................... 7736
Disassembly......................................................................................................................... 7736
Inspection and Repair............................................................................................................... 7737
Reassembly.......................................................................................................................... 7741
Cylinder Block.......................................................................................................................... 7743
Cylinder Block and Associated Parts................................................................................................. 7743
Disassembly......................................................................................................................... 7743
Inspection and Repair............................................................................................................... 7744
Reassembly.......................................................................................................................... 7745
Main Data and Specification............................................................................................................. 7748
Special Tool............................................................................................................................ 7754
6B ENGINE COOLING........................................................................................................................ 7756
Service Precaution...................................................................................................................... 7756
General Description..................................................................................................................... 7757
Diagnosis............................................................................................................................... 7760
Draining and Refilling Cooling System................................................................................................... 7761
Water Pump.............................................................................................................................. 7762
Water Pump and Associated Parts..................................................................................................... 7762
Removal............................................................................................................................. 7762
Inspection.......................................................................................................................... 7762
Thermostat.............................................................................................................................. 7763
Thermostat and Associated Parts..................................................................................................... 7763
Removal............................................................................................................................. 7763
Inspection.......................................................................................................................... 7763
Installation........................................................................................................................ 7763
Radiator................................................................................................................................ 7764
Radiator and Associated Parts....................................................................................................... 7764
Removal............................................................................................................................. 7764
Inspection.......................................................................................................................... 7765
Installation........................................................................................................................ 7766
Drive Belt and Cooling Fan.............................................................................................................. 7767
Drive Belt and Associated Parts..................................................................................................... 7767
Inspection.......................................................................................................................... 7767
Installation........................................................................................................................ 7767
Main Data and Specifications............................................................................................................ 7768
Special Tool............................................................................................................................ 7769
6C ENGINE FUEL........................................................................................................................... 7770
Service Precaution...................................................................................................................... 7770
General Description..................................................................................................................... 7771
Fuel Metering........................................................................................................................... 7772
Fuel Filter............................................................................................................................. 7773
Fuel Filter and Associated Parts.................................................................................................... 7773
Removal............................................................................................................................. 7773
Inspection.......................................................................................................................... 7773
Installation........................................................................................................................ 7773
Inspection.......................................................................................................................... 7774
In-Tank Fuel Filter................................................................................................................. 7774
Fuel Pump Flow Test................................................................................................................. 7774
Fuel Pump............................................................................................................................... 7775
Fuel Pump and Associated Parts...................................................................................................... 7775
Removal............................................................................................................................. 7775
Installation........................................................................................................................ 7775
Fuel Pump Relay......................................................................................................................... 7776
General Description................................................................................................................. 7776
Fuel Tank............................................................................................................................... 7776
Fuel Tank and Associated Parts...................................................................................................... 7776
Removal............................................................................................................................. 7776
Installation........................................................................................................................ 7777
Fuel Tube / Quick-Connect Fittings...................................................................................................... 7777
Precautions......................................................................................................................... 7777
Cautions During Work................................................................................................................ 7777
Removal............................................................................................................................. 7777
Reuse of Quick Connector................................................................................................................ 7779
Assembling Advice....................................................................................................................... 7779
Fuel Gauge Unit......................................................................................................................... 7780
Fuel Gauge Unit and Associated Parts................................................................................................ 7780
Removal............................................................................................................................. 7780
Installation........................................................................................................................ 7780
Fuel Filler Cap......................................................................................................................... 7781
General Description................................................................................................................. 7781
Inspection.......................................................................................................................... 7781
Main Data and Specifications............................................................................................................ 7781
6D1 ENGINE ELECTRICAL..................................................................................................................... 7782
Battery................................................................................................................................. 7782
General Description................................................................................................................. 7782
Diagnosis........................................................................................................................... 7782
Battery Charging.................................................................................................................... 7783
Jump Starting....................................................................................................................... 7783
Battery Removal..................................................................................................................... 7784
Battery Installation................................................................................................................ 7784
Main Data and Specifications........................................................................................................ 7785
6D2 IGNITION SYSTEM....................................................................................................................... 7786
Service Precaution...................................................................................................................... 7786
General Description..................................................................................................................... 7787
Diagnosis............................................................................................................................... 7787
Ignition Coil........................................................................................................................... 7788
Removal............................................................................................................................. 7788
Inspection and Repair............................................................................................................... 7788
Installation........................................................................................................................ 7788
Spark Plug.............................................................................................................................. 7790
Removal............................................................................................................................. 7790
Inspection and Repair............................................................................................................... 7790
Installation........................................................................................................................ 7790
Crankshaft Position Sensor.............................................................................................................. 7791
Removal............................................................................................................................. 7791
Installation........................................................................................................................ 7791
Main Data and Specifications............................................................................................................ 7792
6D3 STARTING AND CHARGING SYSTEM.......................................................................................................... 7793
Service Precaution...................................................................................................................... 7793
Starting System......................................................................................................................... 7794
General Description..................................................................................................................... 7794
Diagnosis............................................................................................................................... 7796
Starter................................................................................................................................. 7797
Removal............................................................................................................................. 7797
Installation........................................................................................................................ 7797
Disassembled View................................................................................................................... 7798
Disassembly......................................................................................................................... 7799
Inspection and Repair............................................................................................................... 7801
Reassembly.......................................................................................................................... 7805
Main Data and Specifications........................................................................................................ 7807
Charging System......................................................................................................................... 7810
General Description..................................................................................................................... 7810
General On-Vehicle Inspection........................................................................................................... 7810
Generator............................................................................................................................... 7811
Removal............................................................................................................................. 7811
Inspection.......................................................................................................................... 7811
Installation........................................................................................................................ 7811
Disassembled View................................................................................................................... 7812
Disassembly......................................................................................................................... 7813
Inspection and Repair............................................................................................................... 7815
Reassembly.......................................................................................................................... 7817
Bench Test.......................................................................................................................... 7817
Main Data and Specifications........................................................................................................ 7818
6E TROOPER 3.5L ENGINE DRIVEABILITY AND EMISSIONS........................................................................................ 7819
Specifications.......................................................................................................................... 7824
Tightening Specifications........................................................................................................... 7824
Diagrams and Schematics................................................................................................................. 7825
PCM Wiring Diagram (1 of 7)......................................................................................................... 7825
PCM Wiring Diagram (2 of 7)......................................................................................................... 7826
PCM Wiring Diagram (3 of 7)......................................................................................................... 7827
PCM Wiring Diagram (4 of 7)......................................................................................................... 7828
PCM Wiring Diagram (5 of 7)......................................................................................................... 7829
PCM Wiring Diagram (6 of 7)......................................................................................................... 7830
PCM Wiring Diagram (7 of 7)......................................................................................................... 7831
PCM Pinouts............................................................................................................................. 7832
PCM Pinout Table, 80-Way Blue Connector-Row "F1 ~ 20"............................................................................... 7832
PCM Pinout Table, 80-Way Blue Connector-Row "F20 ~ 40".............................................................................. 7834
PCM Pinout Table, 80-Way Blue Connector-Row "F41 ~ 60".............................................................................. 7836
PCM Pinout Table, 80-Way Blue Connector-Row "F61 ~ 80".............................................................................. 7838
PCM Pinout Table, 80-Way Red Connector-Row "S1 ~ 20"................................................................................ 7840
PCM Pinout Table, 80-Way Red Connector-Row "S21 ~ 40"............................................................................... 7842
PCM Pinout Table, 80-Way Red Connector-Row "S41 ~ 60"............................................................................... 7844
PCM Pinout Table, 80-Way Red Connector-Row "F61 ~ 80"............................................................................... 7846
Component Locators...................................................................................................................... 7848
Engine Component Locator............................................................................................................ 7848
Engine Component Locator Table...................................................................................................... 7849
Undercarriage Component Locator..................................................................................................... 7850
Undercarriage Component Locator Table............................................................................................... 7850
Fuse and Relay Panel (Underhood Electrical Center).................................................................................. 7851
Sensors and Miscellaneous Component Locators........................................................................................ 7852
Diagnosis............................................................................................................................... 7855
Strategy-Based Diagnostics.......................................................................................................... 7855
DTC Stored.......................................................................................................................... 7855
No DTC.............................................................................................................................. 7855
No Matching Symptom................................................................................................................. 7855
Intermittents....................................................................................................................... 7855
No Trouble Found.................................................................................................................... 7855
Verifying Vehicle Repair............................................................................................................ 7855
General Service Information............................................................................................................. 7856
OBD II Serviceablity Issues......................................................................................................... 7856
Emissions Control Information Label................................................................................................. 7856
Visual / Physical Engine Compartment Inspection..................................................................................... 7856
Basic Knowledge of Tools Required................................................................................................... 7857
Serial Data Communications.............................................................................................................. 7857
Class II Serial Data Communications................................................................................................. 7857
On-Board Diagnostic (OBD II)............................................................................................................ 7857
On-Board Diagnostic Tests........................................................................................................... 7857
Comprehensive Component Monitor Diagnostic Operation................................................................................ 7857
System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations................................... 7858
Common OBD II Terms................................................................................................................. 7858
The Diagnostic Executive............................................................................................................ 7858
DTC Types........................................................................................................................... 7859
Decimal/Binary/Hexadecimal Conversions.............................................................................................. 7861
Verifying Vehicle Repair............................................................................................................ 7861
Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool......................................................................... 7861
Tech 2.............................................................................................................................. 7862
Tech 2 Features..................................................................................................................... 7863
Getting Started..................................................................................................................... 7863
Operating Procedure (For Example)................................................................................................... 7864
DTC Modes........................................................................................................................... 7865
DTC Information Mode................................................................................................................ 7865
Miscellaneous Test.................................................................................................................. 7866
Lamps Test.......................................................................................................................... 7866
Relays Test......................................................................................................................... 7868
EVAP Test........................................................................................................................... 7869
Fuel System Test.................................................................................................................... 7870
Instruments Test.................................................................................................................... 7872
EGR Control Test.................................................................................................................... 7874
Variable Intake Manifold Solenoid Test.............................................................................................. 7874
Injector Balance Test............................................................................................................... 7876
Plotting Snapshot Graph................................................................................................................. 7876
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)...................................................... 7877
Flow Chart for Snapshot Replay (Plotting Graph)..................................................................................... 7878
Primary System-Based Diagnostic......................................................................................................... 7879
Fuel Control Heated Oxygen Sensor................................................................................................... 7879
HO2S Heater......................................................................................................................... 7879
Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation..................................................................... 7879
Evaporative Emission (EVAP) Purge System Vacuum Switch.............................................................................. 7880
Misfire Monitor Diagnostic Operation.................................................................................................... 7880
Misfire Counters.................................................................................................................... 7880
Fuel Trim System Monitor Diagnostic Operation........................................................................................... 7881
Fuel Trim Cell Diagnostic Weights................................................................................................... 7881
On-Board Diagnostic (OBD II) System Check............................................................................................... 7882
A/C Clutch Control Circuit Diagnosis.................................................................................................... 7885
Electronic Ignition System Diagnosis.................................................................................................... 7890
EVAP Canister Purge Solenoid and EVAP Vacuum Switch..................................................................................... 7890
Visual Check of The Evaporative Emission Canister....................................................................................... 7890
Fuel Metering System Check.............................................................................................................. 7890
Fuel System Pressure Test............................................................................................................... 7890
Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure.............................................................. 7890
Powertrain Control Module (PCM) Diagnosis............................................................................................... 7895
Multiple PCM Information Sensor DTCs Set................................................................................................ 7895
Exhaust Gas Recirculation (EGR) Diagnosis............................................................................................... 7899
Engine Tech 2 Data Definitions and Ranges............................................................................................... 7899
Typical Scan Data Values................................................................................................................ 7901
No Malfunction Indicator Lamp (MIL)..................................................................................................... 7907
Malfunction Indicator Lamp (MIL) "ON" Steady............................................................................................ 7910
No Reduced Power Lamp (RPL)............................................................................................................. 7912
Reduced Power Lamp (RPL) "ON" Steady.................................................................................................... 7915
Engine Cranks But Will Not Run.......................................................................................................... 7917
Fuel System Electrical Test............................................................................................................. 7924
Electric Throttle Control (ETC) System Check............................................................................................ 7928
Fuel System Diagnosis................................................................................................................... 7932
Exhaust Gas Recirculation (EGR) System Check............................................................................................ 7937
Manifold Absolute Pressure (MAP) Output Check........................................................................................... 7939
Evaporative (EVAP) Emissions Canister Purge Valve Check................................................................................. 7941
Upshift Lamp System Check (Manual Transmission Only).................................................................................... 7944
PCM Diagnostic Trouble Codes............................................................................................................ 7947
Diagnostic Trouble Code (DTC) P0101 MAF System Performance.............................................................................. 7951
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency.................................................................... 7954
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency................................................................... 7957
Diagnostic Trouble Code (DTC) P0106 MAP System Performance.............................................................................. 7960
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage...................................................................... 7963
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage..................................................................... 7966
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage...................................................................... 7969
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage..................................................................... 7972
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage...................................................................... 7975
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage..................................................................... 7978
Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control...................................................... 7981
Diagnostic Trouble Code(DTC) P0128 Thermostat Insufficient temperrature for Stable Opreation............................................ 7984
Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1............................................................ 7987
Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1........................................................... 7990
Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1.................................................................. 7993
Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1.................................................. 7997
Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1................................................................. 8000
Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2............................................................ 8003
Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2........................................................... 8006
Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2................................................... 8009
Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2................................................................. 8012
Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1............................................................ 8015
Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1........................................................... 8018
Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1.................................................................. 8021
Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1.................................................. 8025
Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Bank 2 Sensor 1................................................................. 8028
Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2............................................................ 8031
Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2........................................................... 8034
Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2.................................................. 8037
Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2................................................................. 8040
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1........................................................................ 8043
Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1........................................................................ 8047
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2........................................................................ 8051
Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2........................................................................ 8055
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit.......................................................................... 8059
Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit.......................................................................... 8062
Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit.......................................................................... 8065
Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit.......................................................................... 8068
Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit.......................................................................... 8071
Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit.......................................................................... 8074
Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected............................................................................. 8077
Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected........................................................................... 8081
Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected........................................................................... 8083
Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected........................................................................... 8085
Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected........................................................................... 8087
Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected........................................................................... 8089
Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected........................................................................... 8091
Diagnostic Trouble Code (DTC) P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault........................................ 8093
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit........................................................................ 8096
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency.................................................................... 8099
Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performance...................................................................... 8102
Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low.............................................................................. 8106
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit.......................................................................... 8110
Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit.......................................................................... 8113
Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit.......................................................................... 8116
Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit.......................................................................... 8119
Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit.......................................................................... 8122
Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit.......................................................................... 8125
Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient............................................................................... 8128
Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error.............................................................................. 8131
Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck...................................................................................... 8133
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage..................................................................................... 8135
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage.................................................................................... 8138
Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1.................................................................... 8141
Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2.................................................................... 8144
Diagnostic Trouble Code (DTC) P0440 EVAP System......................................................................................... 8147
Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected..................................................................... 8150
Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Blocked.......................................................................... 8153
Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) Low Voltage....................................... 8156
Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) High Voltage...................................... 8159
Diagnostic Trouble Code (DTC) P0456 EVAP Very Small Leak................................................................................ 8162
Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit-Low Voltage............................................................... 8165
Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit-High Voktage.............................................................. 8168
Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input............................................................................... 8170
Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM..................................................................... 8173
Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM.................................................................... 8176
Diagnostic Trouble Code (DTC) P0562 System Voltage Low.................................................................................. 8179
Diagnostic Trouble Code (DTC) P0563 System Voltage High................................................................................. 8181
Diagnostic Trouble Code (DTC) P0601 PCM Memory.......................................................................................... 8183
Diagnostic Trouble Code (DTC) P0602 PCM Programming Error............................................................................... 8185
Diagnostic Trouble Code (DTC) P0604 PCM RAM Error....................................................................................... 8187
Diagnostic Trouble Code (DTC) P0606 PCM Internal Performance............................................................................ 8189
Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage........................................................ 8191
Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage................................................................ 8193
Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage........................................................ 8195
Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage......................................................... 8198
Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage......................................................... 8200
Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage........................................................ 8202
Diagnostic Trouble Code(DTC) P1120-TPS 1 Throttle Position Sensor (TPS1) Circuit Fault.................................................. 8205
Diagnostic Trouble Code (DTC) P1125 ETC (Electric Throttle Control) Limit Performance Mode.............................................. 8208
Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1......................................................... 8211
Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1.......................................................... 8215
Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1......................................................... 8219
Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1.................................................. 8223
Diagnostic Trouble Code (DTC) P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1)................................................. 8227
Diagnostic Trouble Code (DTC) P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2)................................................. 8229
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration................................................................ 8231
Diagnostic Trouble Code (DTC) P1220 Throttle Position Senser2 (TPS2) Circuit Fault...................................................... 8234
Diagnosis Truble Code(DTC) P1221 TPS1-TPS2 correlation(Circuit Performance)............................................................. 8237
Diagnostic Trouble Code (DTC) P1271 APS 1-2 Correlation Error........................................................................... 8240
Diagnostic Trouble Code (DTC) P1272 APS 2-3 Correlation Error........................................................................... 8243
Diagnostic Trouble Code (DTC) P1273 APS 1-3 Correlation Error........................................................................... 8246
Diagnostic Trouble Code (DTC) P1275 APS 1 Circuit Fault................................................................................. 8249
Diagnostic Trouble Code (DTC) P1280 APS 2 Circuit Fault................................................................................. 8251
Diagnostic Trouble Code (DTC) P1285 APS 3 Circuit Fault................................................................................. 8253
Diagnostic Trouble Code (DTC) P1290 ETC Forced Idle Mode................................................................................ 8255
Diagnostic Trouble Code (DTC) P1295 Power Management Mode............................................................................... 8258
Diagnostic Trouble Code (DTC) P1299 ETC Forced Engine Shutdown Mode..................................................................... 8262
Diagnostic Trouble Code (DTC) P1310 ION Sensing Module Diagnosis........................................................................ 8266
Diagnostic Trouble Code (DTC) P1311 ION Sensing Module SEC line 1 Circuit Fault......................................................... 8270
Diagnostic Trouble Code (DTC) P1312 ION Sensing Module SEC line 2 Circuit Fault......................................................... 8273
Diagnostic Trouble Code (DTC) P1326 ION Sensing Module Combustion Quality Input Circuit Fault........................................... 8276
Diagnostic Trouble Code (DTC) P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)................................ 8279
Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed.................................................................................... 8282
Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge................................................................... 8285
Diagnostic Trouble Code (DTC) P1514 TPS - MAF Correlation Error......................................................................... 8288
Diagnostic Trouble Code (DTC) P1515 Command - Actual TPS Correlation Error.............................................................. 8292
Diagnostic Trouble Code (DTC) P1516 Command - Actual TPS Correlation Error.............................................................. 8295
Diagnostic Trouble Code (DTC) P1523 Actuator Control Return Performance................................................................. 8298
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset................................................................................ 8301
Diagnostic Trouble Code (DTC) P1635 Reference Voltage # 1 Circuit Fault................................................................. 8302
Diagnostic Trouble Code (DTC) P1639 Reference Voltage # 2 Circuit Fault................................................................. 8304
Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM)................................................................. 8306
Diagnostic Trouble Code (DTC) P1650 Quad Driver Module "A" Fault........................................................................ 8309
Symptom Diagnosis....................................................................................................................... 8312
Default Matrix Table.................................................................................................................... 8341
On-Vehicle ServiceCamshaft Position (CMP) Sensor........................................................................................ 8344
Crankshaft Position (CKP) Sensor........................................................................................................ 8345
Engine Coolant Temperature (ECT) Sensor................................................................................................. 8345
Heated Oxygen Sensor (HO2S)............................................................................................................. 8346
Intake Air Temperature (IAT) Sensor..................................................................................................... 8349
ION Sensing Module...................................................................................................................... 8349
Mass Air Flow (MAF) Sensor.............................................................................................................. 8350
Manifold Absolute Pressure (MAP) Sensor................................................................................................. 8351
Malfunction Indicator Lamp (MIL)........................................................................................................ 8352
Reduced Power Lamp...................................................................................................................... 8352
Powertrain Control Module (PCM)......................................................................................................... 8352
EEPROM.................................................................................................................................. 8353
Throttle Position (TP) Sensor........................................................................................................... 8354
Vehicle Speed Sensor (VSS).............................................................................................................. 8354
Air Cleaner/Air Filter.................................................................................................................. 8356
Common Chamber.......................................................................................................................... 8356
Accelerator Pedal Replacement........................................................................................................... 8357
Fuel Filler Cap......................................................................................................................... 8358
Fuel Filter............................................................................................................................. 8358
Fuel Gauge Unit......................................................................................................................... 8360
Fuel Injectors.......................................................................................................................... 8361
Fuel Metering System.................................................................................................................... 8362
Fuel Pump Assembly...................................................................................................................... 8363
Fuel Pump Relay......................................................................................................................... 8363
Fuel Rail Assembly...................................................................................................................... 8364
Fuel Tank............................................................................................................................... 8365
Throttle Body (TB)...................................................................................................................... 8367
Electronic Ignition System.............................................................................................................. 8369
Catalytic Converter..................................................................................................................... 8370
Air Conditioning Thermo Relay........................................................................................................... 8370
EVAP Canister Hoses..................................................................................................................... 8370
EVAP Canister........................................................................................................................... 8371
EVAP Canister Vent Solenoid............................................................................................................. 8372
Fuel Tank Pressure Sensor............................................................................................................... 8373
EVAP Canister Purge Solenoid............................................................................................................ 8373
Fuel Tank Vent Valve.................................................................................................................... 8374
Linear Exhaust Gas Recirculation (EGR) Valve............................................................................................ 8374
Positive Crankcase Ventilation (PCV) Valve.............................................................................................. 8375
Wiring and Connectors................................................................................................................... 8376
PCM Connectors and Terminals............................................................................................................ 8376
Wire Harness Repair: Twisted Shielded Cable............................................................................................. 8376
Twisted Leads........................................................................................................................... 8377
Weather-Pack Connector.................................................................................................................. 8379
Com-Pack III............................................................................................................................ 8380
Metri-Pack.............................................................................................................................. 8380
General Description (PCM and Sensors)................................................................................................... 8381
58X Reference PCM Input............................................................................................................. 8381
A/C Request Signal.................................................................................................................. 8381
Crankshaft Position (CKP) Sensor.................................................................................................... 8381
Camshaft Position (CMP) Sensor and Signal........................................................................................... 8381
Engine Coolant Temperature (ECT) Sensor............................................................................................. 8381
Electrically Erasable Programmable Read Only Memory (EEPROM)........................................................................ 8382
Fuel Control Heated Oxygen Sensors.................................................................................................. 8382
Catalyst Monitor Heated Oxygen Sensors.............................................................................................. 8382
Intake Air Temperature (IAT) Sensor................................................................................................. 8383
Linear Exhaust Gas Recirculation (EGR) Control...................................................................................... 8383
Mass Air Flow (MAF) Sensor.......................................................................................................... 8383
Manifold Absolute Pressure (MAP) Sensor............................................................................................. 8383
Powertrain Control Module (PCM)..................................................................................................... 8384
PCM Function........................................................................................................................ 8384
PCM Components...................................................................................................................... 8384
PCM Voltage Description............................................................................................................. 8384
PCM Input/Outputs................................................................................................................... 8385
PCM Service Precautions............................................................................................................. 8385
Reprogramming The PCM............................................................................................................... 8385
Throttle Position (TP) Sensor....................................................................................................... 8385
Transmission Fluid Temperature (TFT) Sensor......................................................................................... 8385
Transmission Range Switch........................................................................................................... 8385
Vehicle Speed Sensor (VSS).......................................................................................................... 8386
Use of Circuit Testing Tools........................................................................................................ 8386
Aftermarket Electrical and Vacuum Equipment......................................................................................... 8386
Electrostatic Discharge Damage...................................................................................................... 8386
Upshift Lamp........................................................................................................................ 8386
General Description (Air Induction)..................................................................................................... 8386
Air Induction System................................................................................................................ 8386
General Description (Fuel Metering)..................................................................................................... 8387
Acceleration Mode................................................................................................................... 8387
Battery Voltage Correction Mode..................................................................................................... 8387
CMP Signal.......................................................................................................................... 8387
Clear Flood Mode.................................................................................................................... 8387
Deceleration Mode................................................................................................................... 8387
Engine Speed/Vehicle Speed/Fuel Disable Mode........................................................................................ 8387
Fuel Cutoff Mode.................................................................................................................... 8387
Fuel Injector....................................................................................................................... 8387
Fuel Metering System Components..................................................................................................... 8387
Basic System Operation.............................................................................................................. 8388
Fuel Metering System Purpose........................................................................................................ 8388
Fuel Pressure Regulator............................................................................................................. 8388
Fuel Pump Electrical Circuit........................................................................................................ 8388
Fuel Rail........................................................................................................................... 8388
Run Mode............................................................................................................................ 8389
Starting Mode....................................................................................................................... 8389
Throttle Body Unit.................................................................................................................. 8389
General Description (Electronic Ignition System)........................................................................................ 8389
Camshaft Position (CMP) Sensor...................................................................................................... 8389
Crankshaft Position (CKP) Sensor.................................................................................................... 8389
Electronic Ignition................................................................................................................. 8390
Ignition Coils...................................................................................................................... 8390
Ignition Control.................................................................................................................... 8390
Ignition Control PCM Output......................................................................................................... 8391
Powertrain Control Module (PCM)..................................................................................................... 8391
Spark Plug.......................................................................................................................... 8392
A/C Clutch Diagnosis.................................................................................................................... 8393
A/C Clutch Circuit Operation........................................................................................................ 8393
A/C Clutch Circuit Purpose.......................................................................................................... 8393
A/C Request Signal.................................................................................................................. 8393
General Description (Evaporative (EVAP) Emission System)................................................................................ 8394
EVAP Emission Control System Purpose................................................................................................ 8394
EVAP Emission Control System Operation.............................................................................................. 8394
Enhanced Evaporative Emission Control System........................................................................................ 8394
General Description (Exhaust Gas Recirculation (EGR) System)............................................................................ 8397
EGR Purpose......................................................................................................................... 8397
Linear EGR Valve.................................................................................................................... 8398
Linear EGR Control.................................................................................................................. 8398
Linear EGR Valve Operation and Results of Incorrect Operation....................................................................... 8398
EGR Pintle Position Sensor.......................................................................................................... 8398
General Description (Positive Crankcase Ventilation (PCV) System)....................................................................... 8398
Crankcase Ventilation System Purpose................................................................................................ 8398
Crankcase Ventilation System Operation.............................................................................................. 8398
Special Tools........................................................................................................................... 8400
6F ENGINE EXHAUST........................................................................................................................ 8402
General Description..................................................................................................................... 8403
Front Exhaust Pipe...................................................................................................................... 8404
Front Exhaust Pipe and Associated Parts............................................................................................. 8404
Removal............................................................................................................................. 8404
Installation........................................................................................................................ 8404
Three Way Catalytic Converter LH........................................................................................................ 8405
Removal............................................................................................................................. 8405
Installation........................................................................................................................ 8405
Three Way Catalytic Converter RH........................................................................................................ 8406
Removal............................................................................................................................. 8406
Installation........................................................................................................................ 8406
Exhaust Silencer........................................................................................................................ 8407
Exhaust Silencer and Associated Parts............................................................................................... 8407
Removal............................................................................................................................. 8407
Installation........................................................................................................................ 8407
Rear Exhaust pipe....................................................................................................................... 8408
Rear Exhaust pipe and Associated Parts.............................................................................................. 8408
Removal............................................................................................................................. 8408
Installation........................................................................................................................ 8408
Main Data and Specifications............................................................................................................ 8409
6G ENGINE LUBRICATION.................................................................................................................... 8410
Service Precaution...................................................................................................................... 8410
General Description..................................................................................................................... 8411
Oil Pump................................................................................................................................ 8412
Oil Pump and Associated Parts....................................................................................................... 8412
Disassembly......................................................................................................................... 8412
Inspection and Repair............................................................................................................... 8413
Reassembly.......................................................................................................................... 8414
Oil Pan and Crankcase................................................................................................................... 8416
Removal............................................................................................................................. 8416
Installation........................................................................................................................ 8416
Oil Pump................................................................................................................................ 8419
Removal............................................................................................................................. 8419
Installation........................................................................................................................ 8419
Oil Pump Oil Seal....................................................................................................................... 8421
Removal............................................................................................................................. 8421
Installation........................................................................................................................ 8421
Oil Filter.............................................................................................................................. 8422
Removal............................................................................................................................. 8422
Installation........................................................................................................................ 8422
Main Data and Specification............................................................................................................. 8423
6H ENGINE SPEED CONTROL SYSTEM............................................................................................................ 8424
Service Precaution...................................................................................................................... 8424
Accelerator Pedal....................................................................................................................... 8425
Accelerator Pedal and Associated Parts.............................................................................................. 8425
Removal............................................................................................................................. 8425
Installation........................................................................................................................ 8425
6J INDUCTION............................................................................................................................ 8426
Service Precaution...................................................................................................................... 8426
Air Cleaner Element..................................................................................................................... 8427
Removal............................................................................................................................. 8427
Inspection.......................................................................................................................... 8427
Installation........................................................................................................................ 8427
Sec.7 TRANSMISSION............................................................................................................................ 8684
7A AUTOMATIC TRANSMISSION (4L30-E)....................................................................................................... 8428
Service Precaution...................................................................................................................... 8430
Construction............................................................................................................................ 8430
Range Reference Chart................................................................................................................... 8431
Normal Operation Of 2000 4L30-E Transmission ........................................................................................... 8432
Diagnosis............................................................................................................................... 8432
Driver Information...................................................................................................................... 8432
General Diagnosis Procedure............................................................................................................. 8435
Preliminary Inspection Chart............................................................................................................ 8436
Checking Transmission Fluid Level and Condition......................................................................................... 8437
Test Driving............................................................................................................................ 8438
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................ 8439
Mechanical / Hydraulic Diagnosis Symptoms Index......................................................................................... 8440
Stall Test.............................................................................................................................. 8450
Line Pressure Test...................................................................................................................... 8450
Shift Speed Chart....................................................................................................................... 8451
Lockup Speed Chart...................................................................................................................... 8453
Changing Transmission Fluid............................................................................................................. 8454
Selector Lever.......................................................................................................................... 8454
Inspection.......................................................................................................................... 8454
Removal............................................................................................................................. 8454
Installation........................................................................................................................ 8455
Mode Switch............................................................................................................................. 8456
Removal............................................................................................................................. 8456
Installation........................................................................................................................ 8456
Transmission (With Transfer Case / Extension Assembly).................................................................................. 8458
Transmission And Associated Parts................................................................................................... 8458
Removal............................................................................................................................. 8459
Installation........................................................................................................................ 8460
Solenoid (Main Case Valve Body)......................................................................................................... 8465
Removal............................................................................................................................. 8465
Installation........................................................................................................................ 8465
Solenoid (Adapter Case Valve Body)...................................................................................................... 8466
Removal............................................................................................................................. 8466
Installation........................................................................................................................ 8466
Valve Body Assembly (Main Case)......................................................................................................... 8467
Removal............................................................................................................................. 8467
Installation........................................................................................................................ 8467
Valve Body Assembly (Adapter Case)...................................................................................................... 8468
Removal............................................................................................................................. 8468
Installation........................................................................................................................ 8468
Powertrain Control Module (PCM)......................................................................................................... 8468
Removal............................................................................................................................. 8468
Installation........................................................................................................................ 8468
Speed Sensor (Extension Housing)........................................................................................................ 8469
Removal............................................................................................................................. 8469
Installation........................................................................................................................ 8469
Transmission Oil Temperature Sensor (Main Case)......................................................................................... 8469
Removal............................................................................................................................. 8469
Installation........................................................................................................................ 8469
Front Oil Seal (Converter Housing)...................................................................................................... 8470
Removal............................................................................................................................. 8470
Installation........................................................................................................................ 8470
Rear Oil Seal (Extension Housing)....................................................................................................... 8470
Removal............................................................................................................................. 8470
Installation........................................................................................................................ 8471
Transmission (4L30-E)................................................................................................................... 8471
Disassembly......................................................................................................................... 8471
Reassembly.......................................................................................................................... 8475
Converter Housing And Oil Pump Assembly................................................................................................. 8485
Disassembled View................................................................................................................... 8485
Disassembly......................................................................................................................... 8485
Inspection And Repair............................................................................................................... 8485
Reassembly.......................................................................................................................... 8485
Oil Pump................................................................................................................................ 8486
Disassembled View................................................................................................................... 8486
Disassembly......................................................................................................................... 8486
Inspection And Repair............................................................................................................... 8487
Reassembly.......................................................................................................................... 8487
Main Case Valve Body.................................................................................................................... 8488
Disassembled View................................................................................................................... 8488
Disassembly......................................................................................................................... 8488
Inspection And Repair............................................................................................................... 8489
Reassembly.......................................................................................................................... 8489
Adapter Case Valve Body................................................................................................................. 8490
Disassembled View................................................................................................................... 8490
Disassembly......................................................................................................................... 8490
Inspection And Repair............................................................................................................... 8490
Reassembly.......................................................................................................................... 8490
Third Clutch And Sprag Unit............................................................................................................. 8492
Disassembled View................................................................................................................... 8492
Disassembly......................................................................................................................... 8492
Inspection And Repair............................................................................................................... 8492
Reassembly.......................................................................................................................... 8493
Third Clutch............................................................................................................................ 8494
Disassembled View................................................................................................................... 8494
Disassemble......................................................................................................................... 8494
Inspection And Repair............................................................................................................... 8494
Reassembly.......................................................................................................................... 8494
Sprag Unit.............................................................................................................................. 8496
Disassembled View................................................................................................................... 8496
Disassembly......................................................................................................................... 8496
Inspection And Repair............................................................................................................... 8496
Reassembly.......................................................................................................................... 8496
Second Clutch........................................................................................................................... 8497
Disassembled View................................................................................................................... 8497
Disassembly......................................................................................................................... 8497
Inspection And Repair............................................................................................................... 8498
Reassembly.......................................................................................................................... 8498
3-4 Accumulator Piston.................................................................................................................. 8499
Disassembled View................................................................................................................... 8499
Disassembly......................................................................................................................... 8499
Inspection And Repair............................................................................................................... 8500
Reassembly.......................................................................................................................... 8500
Reverse Clutch Piston And Center Support................................................................................................ 8501
Disassembled View................................................................................................................... 8501
Disassembly......................................................................................................................... 8501
Inspection And Repair............................................................................................................... 8502
Reassembly.......................................................................................................................... 8502
Overrun Clutch And Turbine Shaft........................................................................................................ 8503
Disassembled View................................................................................................................... 8503
Disassembly......................................................................................................................... 8504
Inspection And Repair............................................................................................................... 8504
Reassembly.......................................................................................................................... 8504
Main Data And Specification............................................................................................................. 8506
Special Tools........................................................................................................................... 8510
4L30-L Parts List....................................................................................................................... 8513
Extension Housing Assembly Oil Seal..................................................................................................... 8521
Extension Housing Assembly Rear Oil Seal and Associated Parts....................................................................... 8521
Removal............................................................................................................................. 8521
Installation........................................................................................................................ 8521
Extension Housing Assembly.............................................................................................................. 8523
Extension Housing Assembly and Associated Parts..................................................................................... 8523
Removal............................................................................................................................. 8524
Installation........................................................................................................................ 8524
Extension Housing Assembly.............................................................................................................. 8526
Extension Housing Assembly and Associated Parts..................................................................................... 8526
Removal............................................................................................................................. 8527
Installation........................................................................................................................ 8527
Extension Housing Assembly.......................................................................................................... 8529
Disassembly......................................................................................................................... 8530
Reassembly.......................................................................................................................... 8530
Inspection and Repair............................................................................................................... 8531
Main Data and Specifications............................................................................................................ 8532
Special Tools........................................................................................................................... 8533
7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)................................................................................................... 8534
Service Precaution...................................................................................................................... 8535
General Description..................................................................................................................... 8535
Electronic Control Diagram.......................................................................................................... 8536
Powertrain Control Module (PCM)..................................................................................................... 8537
Control System Diagram.............................................................................................................. 8538
Shift Control....................................................................................................................... 8539
Band Apply Control.................................................................................................................. 8539
Torque Converter Clutch Control (Electronically Controlled Capacity Clutch = ECCC).................................................. 8539
Line Pressure Control............................................................................................................... 8539
On-Board Diagnostic System.......................................................................................................... 8539
Fail Safe Mechanism................................................................................................................. 8539
Torque Management Control........................................................................................................... 8539
ATF Warning Control................................................................................................................. 8539
ABS Control......................................................................................................................... 8539
Reverse Lock Out Control............................................................................................................ 8539
Downhill Control.................................................................................................................... 8539
Uphill Control...................................................................................................................... 8539
Shift Mode Control.................................................................................................................. 8540
Gear Shift Control.................................................................................................................. 8541
Winter Drive Mode................................................................................................................... 8542
Backup Mode......................................................................................................................... 8542
Functions of Input / Output Components.............................................................................................. 8543
Diagnosis............................................................................................................................... 8544
Electronic Diagnosis................................................................................................................ 8544
Check Trans Indicator............................................................................................................... 8544
Diagnostic Check.................................................................................................................... 8544
"Check Trans" Check................................................................................................................. 8545
Tech 2 OBD II Connection............................................................................................................ 8546
Transmission Data................................................................................................................... 8551
OBD II Diagnostic Management System................................................................................................. 8552
16 - Terminal Data Link Connector (DLC)............................................................................................. 8553
Malfunction Indicator Lamp (MIL).................................................................................................... 8554
Types Of Diagnostic Trouble Codes (DTCs)............................................................................................ 8554
Clear DTC........................................................................................................................... 8554
DTC Check........................................................................................................................... 8555
PCM Precaution...................................................................................................................... 8555
Information On PCM.................................................................................................................. 8555
Intermittent Conditions............................................................................................................. 8555
Transmission And PCM Identification................................................................................................. 8556
Isuzu Trooper....................................................................................................................... 8556
Diagnostic Trouble Code (DTC) Identification........................................................................................ 8557
DTC P0218 Transmission Fluid Over Temperature........................................................................................... 8558
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position...................................................................... 8560
DTC P0706 Transmission Range Switch (Mode Switch) Performance........................................................................... 8563
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance....................................................................... 8566
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input................................................................. 8569
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................ 8572
DTC P0719 Brake Switch Circuit Low (Stuck On)........................................................................................... 8575
DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input.................................................................... 8578
DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent................................................................. 8581
DTC P0724 Brake Switch Circuit High (Stuck Off)......................................................................................... 8584
DTC P0730 Gear Error Without Input Speed................................................................................................ 8586
DTC P0742 Torque Converter Clutch (TCC) System Stuck On................................................................................. 8589
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical.............................................................. 8591
DTC P0751 Shift Solenoid A Performance (Stuck OFF)...................................................................................... 8593
DTC P0752 Shift Solenoid A Performance (Stuck ON)....................................................................................... 8595
DTC P0753 Shift Solenoid A Electrical................................................................................................... 8597
DTC P0756 Shift Solenoid B Performance (Stuck OFF)...................................................................................... 8600
DTC P0757 Shift Solenoid B Performance (Stuck ON)....................................................................................... 8602
DTC P0758 Shift Solenoid B Electrical................................................................................................... 8604
DTC P1850 Brake Band Apply Solenoid Malfunction......................................................................................... 8608
DTC P1860 TCC PWM Solenoid Electrical................................................................................................... 8612
DTC P1870 Transmission Component Slipping (TCC Stuck OFF)............................................................................... 8615
Connector List.......................................................................................................................... 8617
7B MANUAL TRANSMISSION................................................................................................................... 8619
Service Precaution...................................................................................................................... 8619
General Description..................................................................................................................... 8620
Diagnosis............................................................................................................................... 8621
Manual Transmission Assembly............................................................................................................ 8622
Removal............................................................................................................................. 8622
Installation........................................................................................................................ 8626
Disassembled View................................................................................................................... 8631
Disassembly......................................................................................................................... 8634
Inspection.......................................................................................................................... 8652
Reassembly.......................................................................................................................... 8654
Main Data and Specifications............................................................................................................ 8680
Special Tools........................................................................................................................... 8682
7C CLUTCH................................................................................................................................ 8684
Service Precaution...................................................................................................................... 8684
General Description..................................................................................................................... 8685
Diagnosis............................................................................................................................... 8689
Clutch Assembly......................................................................................................................... 8690
Clutch Assembly and Associated Parts................................................................................................ 8690
Removal............................................................................................................................. 8690
Inspection and Repair............................................................................................................... 8691
Installation........................................................................................................................ 8695
Clutch Control.......................................................................................................................... 8698
Clutch Control Parts................................................................................................................ 8698
Removal............................................................................................................................. 8698
Inspection and Repair............................................................................................................... 8698
Installation........................................................................................................................ 8699
Adjustment.......................................................................................................................... 8699
Master Cylinder......................................................................................................................... 8702
Inspection and Repair............................................................................................................... 8702
Slave Cylinder.......................................................................................................................... 8703
Disassembled View................................................................................................................... 8703
Disassembly......................................................................................................................... 8703
Inspection and Repair............................................................................................................... 8703
Reassembly.......................................................................................................................... 8704
Main Data and Specifications............................................................................................................ 8705
Special Tools........................................................................................................................... 8707
Sec.8 BODY AND ACCESSORIES.................................................................................................................... 8708
8A LIGHTING SYSTEM........................................................................................................................ 8708
Service Precaution...................................................................................................................... 8709
Headlight Bulb.......................................................................................................................... 8709
Removal............................................................................................................................. 8709
Installation........................................................................................................................ 8709
Headlight............................................................................................................................... 8710
Headlight and Associated Parts...................................................................................................... 8710
Removal............................................................................................................................. 8710
Installation........................................................................................................................ 8710
Headlight Adjustment................................................................................................................ 8710
Fog Light Bulb.......................................................................................................................... 8711
Removal............................................................................................................................. 8711
Installation........................................................................................................................ 8711
Fog Light Assembly...................................................................................................................... 8712
Removal............................................................................................................................. 8712
Installation........................................................................................................................ 8712
Fog Light Adjustment................................................................................................................ 8712
Front Side Marker Light Bulb............................................................................................................ 8712
Removal............................................................................................................................. 8712
Installation........................................................................................................................ 8712
Parking Light Bulb...................................................................................................................... 8713
Removal and Installation............................................................................................................ 8713
Taillight Bulb.......................................................................................................................... 8713
Removal............................................................................................................................. 8713
Installation........................................................................................................................ 8713
License Plate Light Bulb................................................................................................................ 8714
Removal............................................................................................................................. 8714
Installation........................................................................................................................ 8714
Stoplight Bulb.......................................................................................................................... 8714
Removal and Installation............................................................................................................ 8714
High Mount Stoplight.................................................................................................................... 8714
Removal............................................................................................................................. 8714
Installation........................................................................................................................ 8715
Front Turn Signal Light Bulb............................................................................................................ 8715
Removal............................................................................................................................. 8715
Installation........................................................................................................................ 8715
Rear Turn Signal Light Bulb............................................................................................................. 8716
Removal............................................................................................................................. 8716
Installation........................................................................................................................ 8716
Cornering Light Bulb.................................................................................................................... 8716
Removal............................................................................................................................. 8716
Installation........................................................................................................................ 8716
Backup Light Bulb....................................................................................................................... 8717
Removal............................................................................................................................. 8717
Installation........................................................................................................................ 8717
Dome Light Bulb......................................................................................................................... 8717
Removal............................................................................................................................. 8717
Installation........................................................................................................................ 8717
Luggage Room Light Bulb................................................................................................................. 8718
Removal............................................................................................................................. 8718
Installation........................................................................................................................ 8718
Courtesy Light Bulb..................................................................................................................... 8718
Removal............................................................................................................................. 8718
Installation........................................................................................................................ 8718
Map Light Switch/Bulb................................................................................................................... 8719
Removal............................................................................................................................. 8719
Installation........................................................................................................................ 8719
Cigarette Lighter Illumination Bulb..................................................................................................... 8719
Removal............................................................................................................................. 8719
Installation........................................................................................................................ 8719
Ashtray Illumination Bulb............................................................................................................... 8720
Removal............................................................................................................................. 8720
Installation........................................................................................................................ 8720
Glove Box Illumination Bulb............................................................................................................. 8720
Removal............................................................................................................................. 8720
Installation........................................................................................................................ 8720
Vanity Mirror Illumination Bulb......................................................................................................... 8721
Removal............................................................................................................................. 8721
Installation........................................................................................................................ 8721
Starter Switch.......................................................................................................................... 8721
Removal............................................................................................................................. 8721
Installation........................................................................................................................ 8722
Lighting Switch (Combination Switch).................................................................................................... 8722
Removal............................................................................................................................. 8722
Installation........................................................................................................................ 8723
Fog Light Switch........................................................................................................................ 8723
Removal............................................................................................................................. 8723
Installation........................................................................................................................ 8724
Stoplight Switch (W/O Cruise Control)................................................................................................... 8724
Removal............................................................................................................................. 8724
Installation........................................................................................................................ 8724
Brake Switch (W/Cruise Control)......................................................................................................... 8725
Removal............................................................................................................................. 8725
Installation........................................................................................................................ 8725
Turn Signal Switch/Cornering Light Switch (Combination Switch).......................................................................... 8725
Removal and Installation............................................................................................................ 8725
Hazard Warning Switch................................................................................................................... 8725
Removal............................................................................................................................. 8725
Installation........................................................................................................................ 8726
Tailgate Switch......................................................................................................................... 8726
Removal............................................................................................................................. 8726
Installation........................................................................................................................ 8726
Door Switch............................................................................................................................. 8727
Removal............................................................................................................................. 8727
Installation........................................................................................................................ 8727
Rear Defogger Switch.................................................................................................................... 8727
Removal............................................................................................................................. 8727
Installation........................................................................................................................ 8728
Seat Heater Switch...................................................................................................................... 8728
Removal............................................................................................................................. 8728
Installation........................................................................................................................ 8728
Key Remind Switch (Starter Switch)...................................................................................................... 8728
Removal and Installation............................................................................................................ 8728
Illumination Controller................................................................................................................. 8729
Removal............................................................................................................................. 8729
Installation........................................................................................................................ 8729
Main Data and Specifications............................................................................................................ 8730
8B WIPER / WASHER SYSTEM.................................................................................................................. 8732
Service Precaution...................................................................................................................... 8732
Windshield Wiper/Washer System.......................................................................................................... 8733
General Description................................................................................................................. 8733
Windshield Wiper And Washer Switch...................................................................................................... 8733
Removal and Installation............................................................................................................ 8733
Windshield Wiper Motor.................................................................................................................. 8733
Removal............................................................................................................................. 8733
Installation........................................................................................................................ 8733
Windshield Washer Motor................................................................................................................. 8734
Removal............................................................................................................................. 8734
Installation........................................................................................................................ 8734
Windshield Wiper Linkage................................................................................................................ 8735
Windshield Wiper Linkage and Associated Parts....................................................................................... 8735
Removal............................................................................................................................. 8735
Installation........................................................................................................................ 8735
Windshield Wiper Arm/Blade.............................................................................................................. 8736
Removal............................................................................................................................. 8736
Installation........................................................................................................................ 8736
Windshield Wiper Blade Rubber........................................................................................................... 8737
Removal............................................................................................................................. 8737
Installation........................................................................................................................ 8737
Rear Wiper/Washer System................................................................................................................ 8738
General Description................................................................................................................. 8738
Rear Wiper and Washer Switch............................................................................................................ 8738
Removal............................................................................................................................. 8738
Installation........................................................................................................................ 8738
Rear Wiper Motor........................................................................................................................ 8739
Removal............................................................................................................................. 8739
Installation........................................................................................................................ 8739
Alarm & Relay Control Unit.............................................................................................................. 8740
Removal............................................................................................................................. 8740
Installation........................................................................................................................ 8740
Rear Washer Motor....................................................................................................................... 8740
Removal............................................................................................................................. 8740
Installation........................................................................................................................ 8740
Rear Wiper Arm/Blade.................................................................................................................... 8741
Removal............................................................................................................................. 8741
Installation........................................................................................................................ 8741
Rear Washer Nozzle...................................................................................................................... 8741
Removal............................................................................................................................. 8741
Installation........................................................................................................................ 8741
Rear Washer Nozzle Angle Adjustment................................................................................................. 8741
Rear Wiper Blade Rubber................................................................................................................. 8742
Removal and Installation............................................................................................................ 8742
Main Data and Specifications............................................................................................................ 8742
8C ENTERTAINMENT.......................................................................................................................... 8743
Service Precaution...................................................................................................................... 8743
Cigarette Lighter....................................................................................................................... 8744
General Description................................................................................................................. 8744
Removal............................................................................................................................. 8744
Installation........................................................................................................................ 8744
Digital Clock........................................................................................................................... 8744
Removal............................................................................................................................. 8744
Installation........................................................................................................................ 8745
Rod Type Antenna........................................................................................................................ 8745
Removal............................................................................................................................. 8745
Installation........................................................................................................................ 8745
Diversity Glass Antenna................................................................................................................. 8746
Glass Antenna System Parts Location................................................................................................. 8746
Glass Antenna Pattern............................................................................................................... 8747
Glass Antenna Amplifier Removal..................................................................................................... 8747
Glass Antenna Amplifier Installation................................................................................................ 8747
Radio................................................................................................................................... 8748
Removal............................................................................................................................. 8748
Installation........................................................................................................................ 8748
Front Speaker........................................................................................................................... 8749
Removal............................................................................................................................. 8749
Installation........................................................................................................................ 8749
Tweeter Assembly........................................................................................................................ 8749
Removal............................................................................................................................. 8749
Installation........................................................................................................................ 8749
Rear Speaker............................................................................................................................ 8750
Removal............................................................................................................................. 8750
Installation........................................................................................................................ 8750
8D WIRING SYSTEM.......................................................................................................................... 8751
Fuse, Relay and Diode................................................................................................................... 8752
Relay and Fuse Box / Fuse Box Location.............................................................................................. 8752
Relay & Fuse Box.................................................................................................................... 8753
Fuse Box............................................................................................................................ 8754
Circuit Diagram......................................................................................................................... 8755
8E METER AND GAUGE........................................................................................................................ 8788
Service Precaution...................................................................................................................... 8788
General Description..................................................................................................................... 8788
Meter Assembly.......................................................................................................................... 8789
General Description................................................................................................................. 8789
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights.................................................. 8789
Table for Meter/Gauge Connector Terminal Connections................................................................................ 8793
Removal............................................................................................................................. 8797
Installation........................................................................................................................ 8797
Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb, A/T Indicator Light Bulb............................................. 8797
Removal............................................................................................................................. 8797
Installation........................................................................................................................ 8797
Vehicle Speed Sensor.................................................................................................................... 8798
Removal............................................................................................................................. 8798
Installation........................................................................................................................ 8798
Fuel Tank Unit.......................................................................................................................... 8798
Removal............................................................................................................................. 8798
Installation........................................................................................................................ 8798
Multi Meter............................................................................................................................. 8799
Removal............................................................................................................................. 8799
Installation........................................................................................................................ 8799
Ambient Sensor.......................................................................................................................... 8799
Removal............................................................................................................................. 8799
Installation........................................................................................................................ 8799
Main Data and Specifications............................................................................................................ 8800
8F BODY STRUCTURE......................................................................................................................... 8801
Service Precaution...................................................................................................................... 8803
Frame................................................................................................................................... 8803
General Description................................................................................................................. 8803
Frame Dimensions.................................................................................................................... 8804
General Description..................................................................................................................... 8805
Front Bumper............................................................................................................................ 8805
Parts Location...................................................................................................................... 8805
Removal............................................................................................................................. 8806
Installation........................................................................................................................ 8806
Front Bumper Slider Bracket............................................................................................................. 8806
Removal............................................................................................................................. 8806
Installation........................................................................................................................ 8806
Rear Bumper............................................................................................................................. 8807
Parts Location...................................................................................................................... 8807
Removal............................................................................................................................. 8807
Installation........................................................................................................................ 8808
Rear Bumper Slider...................................................................................................................... 8809
Removal............................................................................................................................. 8809
Installation........................................................................................................................ 8809
General Description..................................................................................................................... 8810
Cowl Cover.............................................................................................................................. 8810
Parts Location...................................................................................................................... 8810
Removal............................................................................................................................. 8810
Installation........................................................................................................................ 8811
Engine Hood............................................................................................................................. 8811
Removal............................................................................................................................. 8811
Installation........................................................................................................................ 8811
Engine Hood Hinge....................................................................................................................... 8812
Parts Location...................................................................................................................... 8812
Removal............................................................................................................................. 8812
Installation........................................................................................................................ 8812
Engine Hood Lock........................................................................................................................ 8813
Parts Location...................................................................................................................... 8813
Removal............................................................................................................................. 8813
Installation........................................................................................................................ 8814
Radiator Grille And Front End Lower Panel............................................................................................... 8814
Parts Location...................................................................................................................... 8814
Removal............................................................................................................................. 8814
Installation........................................................................................................................ 8815
Front Fender Panel...................................................................................................................... 8816
Parts Location...................................................................................................................... 8816
Removal............................................................................................................................. 8816
Installation........................................................................................................................ 8817
Body Mounting........................................................................................................................... 8818
Parts Location...................................................................................................................... 8818
Removal (No.1 - No. 2).............................................................................................................. 8818
Removal (No. 3 - No. 6)............................................................................................................. 8819
Installation........................................................................................................................ 8820
General Description..................................................................................................................... 8821
Body Dimension.......................................................................................................................... 8822
Instrument Panel Assembly............................................................................................................... 8840
Parts Location...................................................................................................................... 8840
Removal............................................................................................................................. 8840
Installation........................................................................................................................ 8845
Cross Beam Assembly..................................................................................................................... 8846
Parts Location...................................................................................................................... 8846
Removal............................................................................................................................. 8846
Installation........................................................................................................................ 8847
Front Door Assembly..................................................................................................................... 8848
Parts Location...................................................................................................................... 8848
Removal............................................................................................................................. 8848
Installation........................................................................................................................ 8848
Rear Door Assembly...................................................................................................................... 8849
Parts Location...................................................................................................................... 8849
Removal............................................................................................................................. 8849
Installation........................................................................................................................ 8850
Door Strikers........................................................................................................................... 8850
Adjustment.......................................................................................................................... 8850
Door Check Arm Assembly (Front & Rear).................................................................................................. 8851
Parts Location...................................................................................................................... 8851
Removal............................................................................................................................. 8851
Installation........................................................................................................................ 8852
Front Window Regulator, Glass And Glass Run............................................................................................. 8852
Parts Location...................................................................................................................... 8852
Removal............................................................................................................................. 8852
Installation........................................................................................................................ 8854
Rear Window Regulator And Glass......................................................................................................... 8855
Parts Location...................................................................................................................... 8855
Removal............................................................................................................................. 8855
Installation........................................................................................................................ 8856
Rear Door Fixed Glass And Glass Run..................................................................................................... 8857
Parts Location...................................................................................................................... 8857
Removal............................................................................................................................. 8857
Installation........................................................................................................................ 8858
Front Door Sash Moulding................................................................................................................ 8859
Parts Location...................................................................................................................... 8859
Removal............................................................................................................................. 8859
Installation........................................................................................................................ 8859
Rear Door Moulding...................................................................................................................... 8860
Parts Location...................................................................................................................... 8860
Removal............................................................................................................................. 8860
Installation........................................................................................................................ 8860
Front Door Waist Seal................................................................................................................... 8861
Parts Location...................................................................................................................... 8861
Removal............................................................................................................................. 8861
Installation........................................................................................................................ 8861
Rear Door Waist Seal.................................................................................................................... 8862
Parts Location...................................................................................................................... 8862
Removal and Installation............................................................................................................ 8862
Front Door Weatherstrip................................................................................................................. 8863
Parts Location...................................................................................................................... 8863
Removal............................................................................................................................. 8863
Installation........................................................................................................................ 8864
Rear Door Weatherstrip.................................................................................................................. 8865
Parts Location...................................................................................................................... 8865
Removal and Installation............................................................................................................ 8865
Front Door Seal Finisher................................................................................................................ 8866
Parts Location...................................................................................................................... 8866
Removal............................................................................................................................. 8866
Installation........................................................................................................................ 8866
Rear Door Seal Finisher................................................................................................................. 8867
Parts Location...................................................................................................................... 8867
Removal............................................................................................................................. 8867
Installation........................................................................................................................ 8867
Tailgate Assembly (LH).................................................................................................................. 8868
Parts Location...................................................................................................................... 8868
Removal............................................................................................................................. 8868
Installation........................................................................................................................ 8869
Tailgate Assembly (RH).................................................................................................................. 8870
Parts Location...................................................................................................................... 8870
Removal............................................................................................................................. 8870
Installation........................................................................................................................ 8871
Tailgate Strikers....................................................................................................................... 8872
Adjustment.......................................................................................................................... 8872
Tailgate Stopper Assembly............................................................................................................... 8872
Parts Location...................................................................................................................... 8872
Removal............................................................................................................................. 8872
Installation........................................................................................................................ 8872
Tailgate Dove-Tail...................................................................................................................... 8873
Parts Location...................................................................................................................... 8873
Removal............................................................................................................................. 8873
Installation........................................................................................................................ 8873
Tailgate Dove-Tail Striker.............................................................................................................. 8874
Adjustment.......................................................................................................................... 8874
Tailgate Frame Cover (LH)............................................................................................................... 8875
Parts Location...................................................................................................................... 8875
Removal............................................................................................................................. 8875
Installation........................................................................................................................ 8875
Tailgate Frame Cover (RH)............................................................................................................... 8876
Removal............................................................................................................................. 8876
Installation........................................................................................................................ 8876
Tailgate Sash Trim Cover................................................................................................................ 8877
Parts Location...................................................................................................................... 8877
Removal............................................................................................................................. 8877
Installation........................................................................................................................ 8877
Tailgate Outer Weatherstrip............................................................................................................. 8878
Parts Location...................................................................................................................... 8878
Removal............................................................................................................................. 8878
Installation........................................................................................................................ 8878
Tailgate Center Weatherstrip............................................................................................................ 8879
Parts Location...................................................................................................................... 8879
Removal............................................................................................................................. 8879
Installation........................................................................................................................ 8879
Tailgate Main Weatherstrip.............................................................................................................. 8880
Parts Location...................................................................................................................... 8880
Removal............................................................................................................................. 8880
Installation........................................................................................................................ 8880
Spare Tire Carrier...................................................................................................................... 8881
Parts Location...................................................................................................................... 8881
Removal............................................................................................................................. 8881
Installation........................................................................................................................ 8881
Headlining.............................................................................................................................. 8882
Parts Location...................................................................................................................... 8882
Removal............................................................................................................................. 8882
Installation........................................................................................................................ 8883
Rear Air Deflector...................................................................................................................... 8884
Parts Location...................................................................................................................... 8884
Removal............................................................................................................................. 8884
Installation........................................................................................................................ 8884
Roof Moulding........................................................................................................................... 8886
Parts Location...................................................................................................................... 8886
Removal............................................................................................................................. 8886
Installation........................................................................................................................ 8886
Windshield.............................................................................................................................. 8888
Parts Location...................................................................................................................... 8888
Removal............................................................................................................................. 8888
Installation........................................................................................................................ 8889
Rear Quarter Side Glass................................................................................................................. 8893
Parts Location...................................................................................................................... 8893
Removal............................................................................................................................. 8893
Installation........................................................................................................................ 8893
Tailgate Glass.......................................................................................................................... 8895
Parts Location...................................................................................................................... 8895
Removal............................................................................................................................. 8895
Installation........................................................................................................................ 8896
Main Data and Specifications............................................................................................................ 8897
Special Tools........................................................................................................................... 8907
8G SEATS.................................................................................................................................. 8908
Service Precaution...................................................................................................................... 8908
Front Seat Assembly..................................................................................................................... 8909
Front Seat Assembly and Associated Parts............................................................................................ 8909
Removal............................................................................................................................. 8909
Installation........................................................................................................................ 8909
Disassembled View................................................................................................................... 8910
Disassembly......................................................................................................................... 8911
Reassembly.......................................................................................................................... 8912
Power Seat Assembly..................................................................................................................... 8913
General Description................................................................................................................. 8913
Disassembled View................................................................................................................... 8913
Disassembly......................................................................................................................... 8914
Reassembly.......................................................................................................................... 8916
Power Seat Switch....................................................................................................................... 8916
Removal............................................................................................................................. 8916
Installation........................................................................................................................ 8916
Front Tilt Motor / Rear Tilt Motor / Slide Motor / Recliner Motor....................................................................... 8917
Parts Location...................................................................................................................... 8917
Removal and Installation............................................................................................................ 8917
Seat Heater System...................................................................................................................... 8918
General Description................................................................................................................. 8918
Seat Heater Switch Removal and Installation......................................................................................... 8918
Heat Unit Parts Location............................................................................................................ 8918
Heat Unit Removal and Installation.................................................................................................. 8918
Rear Seat Assembly...................................................................................................................... 8919
Rear Seat Assembly and Associated Parts............................................................................................. 8919
Removal............................................................................................................................. 8919
Installation........................................................................................................................ 8919
Disassembled View (Split Type)...................................................................................................... 8920
Disassembly (Split Type)............................................................................................................ 8921
Reassembly (Split Type)............................................................................................................. 8922
Disassembled View (Bench Type)...................................................................................................... 8923
Disassembly (Bench Type)............................................................................................................ 8924
Reassembly (Bench Type)............................................................................................................. 8925
Rear Seat Foot Rest..................................................................................................................... 8925
Rear Seat Foot Rest and Associated Parts............................................................................................ 8925
Removal............................................................................................................................. 8926
Installation........................................................................................................................ 8926
Main Data and Specifications............................................................................................................ 8926
8H SECURITY AND LOCKS..................................................................................................................... 8928
Service Precaution...................................................................................................................... 8929
Front Door Lock Assembly................................................................................................................ 8929
Front Door Lock Assembly and Associated Parts....................................................................................... 8929
Removal............................................................................................................................. 8929
Installation........................................................................................................................ 8930
Front Outside Handle and Door Lock Cylinder............................................................................................. 8931
Front Outside Handle, Door Lock Cylinder and Associated Parts....................................................................... 8931
Removal............................................................................................................................. 8931
Installation........................................................................................................................ 8933
Rear Door Lock Assembly................................................................................................................. 8934
Rear Door Lock Assembly and Associated Parts........................................................................................ 8934
Removal............................................................................................................................. 8934
Installation........................................................................................................................ 8935
Rear Outside Handle..................................................................................................................... 8936
Rear Outside Handle and Associated Parts............................................................................................ 8936
Removal............................................................................................................................. 8936
Installation........................................................................................................................ 8937
Rear Door Inside Lock Knob Link......................................................................................................... 8937
Removal............................................................................................................................. 8937
Installation........................................................................................................................ 8937
Door Inside Lock Knob................................................................................................................... 8938
Removal............................................................................................................................. 8938
Installation........................................................................................................................ 8938
Door Inside Handle...................................................................................................................... 8938
Removal and Installation............................................................................................................ 8938
Tailgate Lock Assembly (LH)............................................................................................................. 8939
Tailgate Lock Assembly (LH) and Associated Parts.................................................................................... 8939
Removal............................................................................................................................. 8939
Installation........................................................................................................................ 8940
Tailgate Lock Assembly (RH)............................................................................................................. 8941
Tailgate Lock Assembly (RH) and Associated Parts.................................................................................... 8941
Removal............................................................................................................................. 8941
Installation........................................................................................................................ 8942
Tailgate Inside Lock Knob............................................................................................................... 8943
Removal............................................................................................................................. 8943
Installation........................................................................................................................ 8943
Tailgate Outside Handle and/or Tailgate Lock Cylinder................................................................................... 8944
Tailgate Outside Handle and/or Tailgate Lock Cylinder and Associated Parts.......................................................... 8944
Removal............................................................................................................................. 8944
Installation........................................................................................................................ 8945
Key..................................................................................................................................... 8946
Key Coding.......................................................................................................................... 8946
Key Styles.......................................................................................................................... 8946
Power Door Lock System.................................................................................................................. 8947
General Description................................................................................................................. 8947
Front Door Lock Actuator Removal.................................................................................................... 8947
Front Door Lock Actuator Installation............................................................................................... 8947
Rear Door Lock Actuator Removal..................................................................................................... 8947
Rear Door Lock Actuator Installation................................................................................................ 8948
Tailgate Lock Actuator Removal...................................................................................................... 8948
Tailgate Lock Actuator Installation................................................................................................. 8948
Anti-theft System....................................................................................................................... 8949
General Description................................................................................................................. 8949
Anti-theft & Keyless Entry Control Unit Removal..................................................................................... 8949
Anti-theft & Keyless Entry Control Unit Installation................................................................................ 8949
Anti-theft Indicator Removal........................................................................................................ 8949
Anti-theft Indicator Installation................................................................................................... 8950
Anti-theft Horn Removal............................................................................................................. 8950
Anti-Theft Horn Installation........................................................................................................ 8950
Engine Hood Switch Removal.......................................................................................................... 8950
Engine Hood Switch Installation..................................................................................................... 8950
Keyless Entry System.................................................................................................................... 8951
ID Code Registration................................................................................................................ 8951
Anti-theft & Keyless Entry Control Unit/Transmitter Replacement..................................................................... 8953
Main Data and Specifications............................................................................................................ 8954
8I SUN ROOF/CONVERTIBLE TOP.............................................................................................................. 8955
Service Precaution...................................................................................................................... 8955
Sun Roof Glass.......................................................................................................................... 8956
Sun Roof Glass and Associated Parts................................................................................................. 8956
Removal............................................................................................................................. 8956
Installation........................................................................................................................ 8957
Sun Roof Deflector...................................................................................................................... 8958
Removal............................................................................................................................. 8958
Installation........................................................................................................................ 8958
Sunshade................................................................................................................................ 8958
Disassembled View................................................................................................................... 8958
Removal............................................................................................................................. 8959
Installation........................................................................................................................ 8959
Sun Roof Frame Complete Assembly........................................................................................................ 8960
Sun Roof Frame Complete Assembly and Associated Parts............................................................................... 8960
Removal............................................................................................................................. 8960
Installation........................................................................................................................ 8961
Disassembled View................................................................................................................... 8961
Disassembly......................................................................................................................... 8961
Reassembly.......................................................................................................................... 8962
Sun Roof Drain Hose (Front Side)........................................................................................................ 8963
Sun Roof Drain Hose (Front Side) and Associated Parts............................................................................... 8963
Removal............................................................................................................................. 8963
Installation........................................................................................................................ 8963
Sun Roof Drain Hose (Rear Side)......................................................................................................... 8964
Sun Roof Drain Hose (Rear Side) and Associated Parts................................................................................ 8964
Removal............................................................................................................................. 8964
Installation........................................................................................................................ 8964
Sun Roof Switch......................................................................................................................... 8965
General Description................................................................................................................. 8965
Removal............................................................................................................................. 8965
Installation........................................................................................................................ 8965
Sun Roof Motor.......................................................................................................................... 8966
Removal............................................................................................................................. 8966
Installation........................................................................................................................ 8966
Main Data and Specifications............................................................................................................ 8967
8J EXTERIOR / INTERIOR TRIM............................................................................................................... 8968
Service Precaution...................................................................................................................... 8969
Dash Side Trim Panel.................................................................................................................... 8970
Removal............................................................................................................................. 8970
Installation........................................................................................................................ 8970
Assist Grip............................................................................................................................. 8970
Parts Location...................................................................................................................... 8970
Removal and Installation............................................................................................................ 8970
Consoles................................................................................................................................ 8971
Consoles and Associated Parts....................................................................................................... 8971
Removal............................................................................................................................. 8971
Installation........................................................................................................................ 8972
Front Door Trim Panel................................................................................................................... 8973
Front Door Trim Panel and Associated Parts.......................................................................................... 8973
Removal............................................................................................................................. 8973
Installation........................................................................................................................ 8976
Rear Door Trim Panel.................................................................................................................... 8977
Rear Door Trim Panel and Associated Parts........................................................................................... 8977
Removal............................................................................................................................. 8977
Installation........................................................................................................................ 8978
Door Wood Panel Assembly................................................................................................................ 8980
Door Wood Panel Assembly and Associated Parts....................................................................................... 8980
Removal............................................................................................................................. 8980
Installation........................................................................................................................ 8980
Door Mirror............................................................................................................................. 8981
Door Mirror and Associated Parts.................................................................................................... 8981
Removal............................................................................................................................. 8981
Installation........................................................................................................................ 8981
Luggage Side and Quarter Upper Trim Cover............................................................................................... 8982
Luggage Side, Quarter Upper Trim Cover and Associated Parts......................................................................... 8982
Removal............................................................................................................................. 8982
Installation........................................................................................................................ 8984
Center Pillar and Roof Side Trim Cover.................................................................................................. 8984
Center Pillar, Roof Side Trim Cover and Associated Parts............................................................................ 8984
Removal............................................................................................................................. 8985
Installation........................................................................................................................ 8986
Front Pillar Trim Cover................................................................................................................. 8986
Front Pillar Trim Cover and Associated Parts........................................................................................ 8986
Removal............................................................................................................................. 8986
Installation........................................................................................................................ 8987
Center Pillar Assist Grip............................................................................................................... 8987
Parts Location...................................................................................................................... 8987
Removal and Installation............................................................................................................ 8987
Assist Grip............................................................................................................................. 8988
Parts Location...................................................................................................................... 8988
Removal and Installation............................................................................................................ 8988
Fuel Filler Lid Opener Cable............................................................................................................ 8989
Fuel Filler Lid Opener Cable and Associated Parts................................................................................... 8989
Removal............................................................................................................................. 8989
Installation........................................................................................................................ 8990
Fuel Filler Door........................................................................................................................ 8990
Parts Location...................................................................................................................... 8990
Removal............................................................................................................................. 8990
Installation........................................................................................................................ 8990
Rocker Protector (Without Wheel Opening Extension)...................................................................................... 8991
Rocker Protector (Without Wheel Opening Extension) and Associated Parts............................................................. 8991
Removal............................................................................................................................. 8991
Installation........................................................................................................................ 8991
Wheel Opening Extension and Rocker Protector Assembly................................................................................... 8992
Wheel Opening Extension, Rocker Protector Assembly and Associated Parts............................................................. 8992
Removal............................................................................................................................. 8992
Installation........................................................................................................................ 8993
Mud Flaps (With Wheel Opening Extension)................................................................................................ 8994
Mud Flaps (With Wheel Opening Extension) and Associated Parts....................................................................... 8994
Removal............................................................................................................................. 8994
Installation........................................................................................................................ 8994
Ventilation Assembly.................................................................................................................... 8995
Ventilation Assembly and Associated Parts........................................................................................... 8995
Removal............................................................................................................................. 8995
Installation........................................................................................................................ 8995
Tailgate Trim Panel (LH)................................................................................................................ 8996
Tailgate Trim Panel (LH) and Associated Parts....................................................................................... 8996
Removal............................................................................................................................. 8996
Installation........................................................................................................................ 8996
Tailgate Trim Panel (RH)................................................................................................................ 8997
Parts Location...................................................................................................................... 8997
Removal............................................................................................................................. 8997
Installation........................................................................................................................ 8997
Luggage Floor Box....................................................................................................................... 8998
Luggage Floor Box and Associated Parts.............................................................................................. 8998
Remove.............................................................................................................................. 8998
Installation........................................................................................................................ 8998
Rope Hook Set........................................................................................................................... 8998
Rope Hook Set and Associated Parts.................................................................................................. 8998
Removal............................................................................................................................. 8998
Installation........................................................................................................................ 8998
Power Door Mirror System................................................................................................................ 8999
General Description................................................................................................................. 8999
Door Mirror Switch Assembly (Control Switch, Folding Switch and Defogger Switch) Removal............................................ 8999
Installation........................................................................................................................ 8999
Power Door Mirror....................................................................................................................... 8999
General Description................................................................................................................. 8999
Removal and Installation............................................................................................................ 8999
Power Window System..................................................................................................................... 9000
General Description................................................................................................................. 9000
Power Window Switch Removal and Installation........................................................................................ 9000
Power Window Motor Removal and Installation......................................................................................... 9001
Main Data and Specifications............................................................................................................ 9002
Sec.9 RESTRAINTS.............................................................................................................................. 9053
9A SEAT BELT SYSTEM...................................................................................................................... 9003
Service Precaution...................................................................................................................... 9003
Seat Belt............................................................................................................................... 9004
Front Seat Belt and Associated Parts................................................................................................ 9004
Removal............................................................................................................................. 9004
Inspection.......................................................................................................................... 9004
Installation........................................................................................................................ 9005
Rear Seat Belt and Associated Parts................................................................................................. 9005
Removal............................................................................................................................. 9006
Inspection.......................................................................................................................... 9006
Installation........................................................................................................................ 9006
Front Seat Buckle Assembly.............................................................................................................. 9006
Removal............................................................................................................................. 9006
Installation........................................................................................................................ 9006
Rear Center Seat Belt / Buckle Assembly................................................................................................. 9007
Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................ 9007
Removal............................................................................................................................. 9007
Installation........................................................................................................................ 9007
Rear Seat Lock Assembly................................................................................................................. 9008
Removal............................................................................................................................. 9008
Installation........................................................................................................................ 9008
Rear Seat Lock Assembly (Bench Type).................................................................................................... 9008
Removal............................................................................................................................. 9008
Installation........................................................................................................................ 9008
Rear Seat Strikers...................................................................................................................... 9009
Removal............................................................................................................................. 9009
Installation........................................................................................................................ 9009
Child Seat Tether Anchor Bracket (Child Restraint)...................................................................................... 9009
General Description................................................................................................................. 9009
Child Seat Tether Anchor Bracket and Associated Parts............................................................................... 9009
Installation........................................................................................................................ 9009
Main Data and Specifications............................................................................................................ 9010
9J SUPPLEMENTAL RESTRAINT SYSTEM (SRS)................................................................................................... 9011
Service Precaution...................................................................................................................... 9011
General Description..................................................................................................................... 9012
SRS Component And Wiring Location View.................................................................................................. 9014
Component Description................................................................................................................... 9014
Definitions............................................................................................................................. 9017
Diagnosis............................................................................................................................... 9018
SRS Connector Body Face Views........................................................................................................... 9019
Repairs And Inspections Required After An Accident...................................................................................... 9019
On-Vehicle Service...................................................................................................................... 9020
Air Bag Assembly Handling / Shipping / Scrapping........................................................................................ 9021
Special Tools........................................................................................................................... 9030
Service Precautions for SRS Component Service........................................................................................... 9034
SRS Connectors.......................................................................................................................... 9035
Sensing And Diagnostic Module (SDM)..................................................................................................... 9037
Service Precautions................................................................................................................. 9037
Removal............................................................................................................................. 9037
Installation........................................................................................................................ 9037
Driver Air Bag Assembly................................................................................................................. 9039
Service Precautions................................................................................................................. 9039
Removal............................................................................................................................. 9039
Installation........................................................................................................................ 9040
Steering Wheel.......................................................................................................................... 9041
Service Precautions................................................................................................................. 9041
Removal............................................................................................................................. 9041
Installation........................................................................................................................ 9042
SRS Coil Assembly....................................................................................................................... 9044
Service Precautions................................................................................................................. 9044
Removal............................................................................................................................. 9044
Installation........................................................................................................................ 9045
Steering Column......................................................................................................................... 9047
Service Precautions................................................................................................................. 9047
Removal............................................................................................................................. 9047
Installation........................................................................................................................ 9049
Passenger Air Bag Assembly.............................................................................................................. 9051
Service Precautions................................................................................................................. 9051
Removal............................................................................................................................. 9051
Installation........................................................................................................................ 9052
Main Data and Specifications............................................................................................................ 9052
9J1 RESTRAINT CONTROL SYSTEM............................................................................................................... 9053
Service Precaution...................................................................................................................... 9053
Diagnostic Information.................................................................................................................. 9054
System Schematic........................................................................................................................ 9056
SRS Diagnostic System Check............................................................................................................. 9056
Chart A SDM Integrity Check............................................................................................................. 9058
Chart B "AIR BAG" Warning Lamp Comes "ON" Steady........................................................................................ 9060
Chart C "AIR BAG" Warning Lamp Does Not Come "ON" Steady (1/2).......................................................................... 9062
DTC 15 Passenger Deployment Loop Resistance High........................................................................................ 9065
DTC 16 Passenger Deployment loop Resistance Low......................................................................................... 9067
DTC 17 Passenger Deployment Loop Open................................................................................................... 9069
DTC 18 Passenger Deployment Loop Short To Ground........................................................................................ 9071
DTC 19 Passenger Deployment Loop Short To Voltage....................................................................................... 9073
DTC 21 Driver Deployment Loop Resistance High........................................................................................... 9075
DTC 22 Driver Deployment Loop Resistance Low............................................................................................ 9078
DTC 24 Driver Deployment Loop Short To Ground........................................................................................... 9080
DTC 25 Driver Deployment Loop Short To Voltage.......................................................................................... 9082
DTC 26 Driver Deployment Loop Open...................................................................................................... 9084
DTC 51 Deployment Event Commanded....................................................................................................... 9086
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range.................................................. 9088
DTC 61 Warning Lamp Circuit Failure..................................................................................................... 9090
DTC 71 Internal SDM Fault............................................................................................................... 9092
Sec.10 CONTROL SYSTEM.......................................................................................................................... 9094
10A CRUISE CONTROL SYSTEM................................................................................................................. 9094
Service Precaution...................................................................................................................... 9094
General Description..................................................................................................................... 9094
Brake Switch............................................................................................................................ 9095
Removal............................................................................................................................. 9095
Installation........................................................................................................................ 9095
Adjustment.......................................................................................................................... 9096
Clutch Switch........................................................................................................................... 9096
Removal and Installation............................................................................................................ 9096
Adjustment.......................................................................................................................... 9096
Starter Switch.......................................................................................................................... 9097
Removal............................................................................................................................. 9097
Installation........................................................................................................................ 9097
Cruise Control Main Switch.............................................................................................................. 9098
Removal............................................................................................................................. 9098
Installation........................................................................................................................ 9098
Cruise Control Switch (Combination Switch).............................................................................................. 9098
Removal and Installation............................................................................................................ 9098
Powertrain Control Module (PCM)......................................................................................................... 9098
Removal and Installation............................................................................................................ 9098
Mode Switch............................................................................................................................. 9098
Removal and Installation............................................................................................................ 9098
Diagnosis............................................................................................................................... 9099
(UE) RODEO.......................................................................................................................................... 9100
Sec.0 GENERAL INFORMATION..................................................................................................................... 9116
0A GENERAL INFORMATION..................................................................................................................... 9101
General Repair Instruction.............................................................................................................. 9101
Illustration Arrows..................................................................................................................... 9102
Identification.......................................................................................................................... 9103
Theft Prevention Standard............................................................................................................... 9106
Lifting Instructions.................................................................................................................... 9111
Standard Bolts Torque Specifications.................................................................................................... 9113
Abbreviations Charts.................................................................................................................... 9114
Service Parts Identification Plate...................................................................................................... 9115
0B MAINTENANCE AND LUBRICATION............................................................................................................. 9116
Maintenance Schedule List............................................................................................................... 9116
Explanation of Complete Vehicle Maintenance Schedule.................................................................................... 9120
Recommended Fluids and Lubricants................................................................................................... 9123
Lubricant Viscosity Chart............................................................................................................... 9124
Recommended Liquid Gasket........................................................................................................... 9126
Recommended Thread Locking Agents................................................................................................... 9126
Maintenance Service Data................................................................................................................ 9127
Sec.1 HVAC SYSTEMS............................................................................................................................ 9128
1A HVAC SYSTEMS........................................................................................................................... 9128
Service Precaution...................................................................................................................... 9129
Heating and Ventilation System.......................................................................................................... 9129
General Description................................................................................................................. 9129
Wiring Diagram...................................................................................................................... 9133
Diagnosis........................................................................................................................... 9134
Individual Inspection............................................................................................................... 9138
Heater Unit............................................................................................................................. 9140
Heater Unit and Associated Parts.................................................................................................... 9140
Removal............................................................................................................................. 9140
Installation........................................................................................................................ 9141
Heater Core and / or Mode Door.......................................................................................................... 9141
Disassembled View................................................................................................................... 9141
Removal............................................................................................................................. 9141
Inspection.......................................................................................................................... 9142
Installation........................................................................................................................ 9142
Heater Mode Control Link Unit........................................................................................................... 9143
Disassembled View................................................................................................................... 9143
Removal............................................................................................................................. 9143
Installation........................................................................................................................ 9144
Heater Temperature Control Link Unit.................................................................................................... 9144
Disassembled View................................................................................................................... 9144
Removal............................................................................................................................. 9144
Installation........................................................................................................................ 9145
Blower Assembly......................................................................................................................... 9145
Blower Assembly and Associated Parts................................................................................................ 9145
Removal............................................................................................................................. 9145
Installation........................................................................................................................ 9146
Blower Link Unit and / or Mode door..................................................................................................... 9146
Disassembled View................................................................................................................... 9146
Removal............................................................................................................................. 9146
Installation........................................................................................................................ 9147
Blower Motor............................................................................................................................ 9148
Blower Motor and Associated Parts................................................................................................... 9148
Removal............................................................................................................................. 9148
Installation........................................................................................................................ 9148
Rear Heater Duct, Defroster Nozzle and Ventilation Duct................................................................................. 9149
Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts........................................................... 9149
Removal............................................................................................................................. 9149
Installation........................................................................................................................ 9150
Control Lever Assembly and / or Control Cable........................................................................................... 9150
Control Lever Assembly, Control Cable and Associated Parts.......................................................................... 9150
Removal............................................................................................................................. 9151
Installation........................................................................................................................ 9152
Control Panel Illumination Bulb......................................................................................................... 9153
Control Panel Illumination Bulb and Associated Parts................................................................................ 9153
Removal............................................................................................................................. 9153
Installation........................................................................................................................ 9153
Resistor................................................................................................................................ 9153
Resistor and Associated Parts....................................................................................................... 9153
Removal............................................................................................................................. 9153
Installation........................................................................................................................ 9153
Air Conditioning System................................................................................................................. 9154
General Description................................................................................................................. 9154
Wiring Diagram...................................................................................................................... 9161
Diagnosis........................................................................................................................... 9164
Air Source Select Lever Diagnosis................................................................................................... 9174
Individual Inspection............................................................................................................... 9177
General Repair Procedure............................................................................................................ 9178
Leak Check.......................................................................................................................... 9180
Compressor Assembly..................................................................................................................... 9185
Compressor Assembly and Associated Parts............................................................................................ 9185
Removal............................................................................................................................. 9185
Installation........................................................................................................................ 9186
New Compressor Installation......................................................................................................... 9186
Condenser Assembly...................................................................................................................... 9187
Condenser Assembly and Associated Parts............................................................................................. 9187
Removal............................................................................................................................. 9187
Installation........................................................................................................................ 9187
Condenser Fan Motor..................................................................................................................... 9188
Condenser Fan Motor and Associated Parts............................................................................................ 9188
Removal............................................................................................................................. 9188
Installation........................................................................................................................ 9188
Receiver / Drier........................................................................................................................ 9189
Receiver / Drier and Associated Parts............................................................................................... 9189
Removal............................................................................................................................. 9189
Installation........................................................................................................................ 9189
Pressure Switch......................................................................................................................... 9190
Pressure Switch and Associated Parts................................................................................................ 9190
Removal............................................................................................................................. 9190
Installation........................................................................................................................ 9190
Evaporator Assembly..................................................................................................................... 9191
Evaporator Assembly and Associated Parts............................................................................................ 9191
Removal............................................................................................................................. 9191
Installation........................................................................................................................ 9192
Electronic Thermostat, Evaporator Core and/or Expansion Valve........................................................................... 9192
Disassembled View................................................................................................................... 9192
Removal............................................................................................................................. 9193
Installation........................................................................................................................ 9193
Refrigerant Line........................................................................................................................ 9194
Refrigerant Line and Associated Parts............................................................................................... 9194
Removal............................................................................................................................. 9195
Installation........................................................................................................................ 9195
Main Data And Specifications............................................................................................................ 9195
Compressor.............................................................................................................................. 9198
Service Precaution.................................................................................................................. 9198
General Description................................................................................................................. 9198
Diagnosis........................................................................................................................... 9199
Magnetic Clutch Assembly (DKV-14G Type)................................................................................................. 9200
Parts Location View................................................................................................................. 9200
Removal............................................................................................................................. 9200
Inspection and Repair............................................................................................................... 9202
Installation........................................................................................................................ 9202
Compressor Oil.......................................................................................................................... 9204
Oil Specification................................................................................................................... 9204
Handling of Oil..................................................................................................................... 9204
Compressor Oil Check................................................................................................................ 9204
Checking and Adjusting Oil Quantity for Used Compressor............................................................................. 9204
Checking and Adjusting for Compressor Replacement................................................................................... 9205
Contamination of Compressor Oil..................................................................................................... 9205
Oil Return Operation................................................................................................................ 9205
Replacement of Component Parts...................................................................................................... 9205
Main Data and Specifications............................................................................................................ 9206
Special Tools........................................................................................................................... 9208
Sec.2 STEERING................................................................................................................................ 9209
2A POWER-ASSISTED STEERING SYSTEM......................................................................................................... 9209
Service Precaution...................................................................................................................... 9210
Diagnosis............................................................................................................................... 9210
General Description..................................................................................................................... 9216
Power Steering System Test.............................................................................................................. 9218
Maintenance............................................................................................................................. 9219
Fluid Level............................................................................................................................. 9219
Bleeding The Power Steering System...................................................................................................... 9219
Bleeding Procedure...................................................................................................................... 9219
Flushing The Power Steering System...................................................................................................... 9219
Steering Wheel Free Play Inspection..................................................................................................... 9220
Front End Alignment Inspection and Adjustment........................................................................................... 9220
Main Data and Specifications............................................................................................................ 9224
Special Tools........................................................................................................................... 9225
Power Steering Unit..................................................................................................................... 9226
Power Steering Unit and Associated Parts............................................................................................ 9226
Removal............................................................................................................................. 9226
Installation (4 × 2 Model).......................................................................................................... 9227
Installation (4 × 4 Model).......................................................................................................... 9227
Power Steering Unit Disassembled View............................................................................................... 9228
Disassembly......................................................................................................................... 9228
Inspection and Repair............................................................................................................... 9228
Reassembly.......................................................................................................................... 9228
Main Data and Specifications........................................................................................................ 9229
Special Tools....................................................................................................................... 9229
Power Steering Pump..................................................................................................................... 9230
Power Steering Pump and Associated Parts............................................................................................ 9230
Removal............................................................................................................................. 9230
Installation........................................................................................................................ 9230
Power Steering Pump Disassembled View............................................................................................... 9231
Disassembly......................................................................................................................... 9231
Inspection and Repair............................................................................................................... 9232
Reassembly.......................................................................................................................... 9232
Main Data and Specifications........................................................................................................ 9234
Transfer Gear Assembly.................................................................................................................. 9235
Transfer Gear Assembly and Associated Parts......................................................................................... 9235
Removal............................................................................................................................. 9235
Inspection and Repair............................................................................................................... 9235
Installation........................................................................................................................ 9235
Supplemental Restraint System Steering Wheel & Column................................................................................... 9236
Service Precaution.................................................................................................................. 9236
SRS Connectors...................................................................................................................... 9236
Inflator Module......................................................................................................................... 9238
Inflator Module and Associated Parts................................................................................................ 9238
Removal............................................................................................................................. 9238
Inspection and Repair............................................................................................................... 9239
Installation........................................................................................................................ 9239
Steering Wheel.......................................................................................................................... 9240
Steering Wheel and Associated Parts................................................................................................. 9240
Removal............................................................................................................................. 9240
Installation........................................................................................................................ 9242
Combination Switch...................................................................................................................... 9243
Combination Switch and Associated Parts............................................................................................. 9243
Removal............................................................................................................................. 9243
Installation........................................................................................................................ 9245
Lock Cylinder........................................................................................................................... 9247
Lock Cylinder and Associated Parts.................................................................................................. 9247
Removal............................................................................................................................. 9247
System Inspection................................................................................................................... 9250
Steering Column......................................................................................................................... 9251
Steering Column and Associated Parts................................................................................................ 9251
Removal............................................................................................................................. 9251
Insepction.......................................................................................................................... 9253
Installation........................................................................................................................ 9255
System Inspection................................................................................................................... 9256
Supplemental Restraint System Steering Wheel & Column and Associated Parts.............................................................. 9257
Main Data and Specifications........................................................................................................ 9257
Special Tools....................................................................................................................... 9257
Sec.3 SUSPENSION.............................................................................................................................. 9314
3C FRONT SUSPENSION....................................................................................................................... 9258
Service Precaution...................................................................................................................... 9258
General Description..................................................................................................................... 9259
Diagnosis............................................................................................................................... 9259
Shock Absorber.......................................................................................................................... 9262
Shock Absorber and Associated Parts................................................................................................. 9262
Removal............................................................................................................................. 9262
Inspection and Repair............................................................................................................... 9262
Installation........................................................................................................................ 9262
Stabilizer Bar.......................................................................................................................... 9263
Stabilizer Bar and Associated Parts................................................................................................. 9263
Removal............................................................................................................................. 9263
Inspection and Repair............................................................................................................... 9263
Installation........................................................................................................................ 9263
Torsion Bar............................................................................................................................. 9264
Torsion Bar and Associated Parts.................................................................................................... 9264
Removal............................................................................................................................. 9264
Inspection and Repair............................................................................................................... 9265
Installation........................................................................................................................ 9265
Knuckle................................................................................................................................. 9267
Knuckle and Associated Parts........................................................................................................ 9267
Removal............................................................................................................................. 9267
Inspection and Repair............................................................................................................... 9268
Installation........................................................................................................................ 9268
Upper Control Arm....................................................................................................................... 9270
Upper Control Arm and Associated Parts.............................................................................................. 9270
Removal............................................................................................................................. 9270
Inspection and Repair............................................................................................................... 9271
Installation........................................................................................................................ 9271
Lower Control Arm....................................................................................................................... 9273
Lower Control Arm and Associated Parts.............................................................................................. 9273
Removal............................................................................................................................. 9273
Inspection and Repair............................................................................................................... 9274
Installation........................................................................................................................ 9275
Upper Ball Joint........................................................................................................................ 9276
Upper Ball Joint and Associated Parts............................................................................................... 9276
Removal............................................................................................................................. 9276
Inspection and Repair............................................................................................................... 9277
Installation........................................................................................................................ 9277
Lower Ball Joint........................................................................................................................ 9278
Lower Ball Joint and Associated Parts............................................................................................... 9278
Removal............................................................................................................................. 9278
Inspection and Repair............................................................................................................... 9279
Installation........................................................................................................................ 9279
Main Data and Specifications............................................................................................................ 9280
Special Tools........................................................................................................................... 9281
3D REAR SUSPENSION........................................................................................................................ 9282
Service Precaution...................................................................................................................... 9282
General Description..................................................................................................................... 9282
Diagnosis............................................................................................................................... 9283
Coil Spring............................................................................................................................. 9286
Coil Spring and Associated Parts.................................................................................................... 9286
Removal............................................................................................................................. 9286
Inspection and Repair............................................................................................................... 9287
Installation........................................................................................................................ 9287
Shock Absorber.......................................................................................................................... 9288
Shock Absorber and Associated Parts................................................................................................. 9288
Removal............................................................................................................................. 9288
Inspection and Repair............................................................................................................... 9288
Installation........................................................................................................................ 9288
Trailing Link........................................................................................................................... 9289
Trailing Link and Associated Parts.................................................................................................. 9289
Removal............................................................................................................................. 9289
Inspection and Repair............................................................................................................... 9289
Installation........................................................................................................................ 9290
Upper Link.............................................................................................................................. 9291
Upper Link and Associated Parts..................................................................................................... 9291
Removal............................................................................................................................. 9291
Inspection and Repair............................................................................................................... 9291
Installation........................................................................................................................ 9292
Lateral Rod............................................................................................................................. 9293
Lateral Rod and Associated Parts.................................................................................................... 9293
Removal............................................................................................................................. 9293
Inspection and Repair............................................................................................................... 9293
Installation........................................................................................................................ 9294
Stabilizer Bar.......................................................................................................................... 9295
Stabilizer Bar and Associated Parts................................................................................................. 9295
Removal............................................................................................................................. 9295
Inspection and Repair............................................................................................................... 9295
Installation........................................................................................................................ 9296
Main Data and Specifications............................................................................................................ 9297
Special Tools........................................................................................................................... 9299
3E WHEEL AND TIRE SYSTEM.................................................................................................................. 9300
Service Precaution...................................................................................................................... 9300
General Description..................................................................................................................... 9301
Diagnosis............................................................................................................................... 9302
Wheel................................................................................................................................... 9310
Wheel and Associated Parts.......................................................................................................... 9310
Removal............................................................................................................................. 9310
Installation........................................................................................................................ 9310
Tire.................................................................................................................................... 9311
Tire Replacement.................................................................................................................... 9311
General Balance Procedure............................................................................................................... 9311
Balancing Wheel and Tire................................................................................................................ 9312
Main Data and Specifications............................................................................................................ 9313
3F INTELLIGENT SUSPENSION SYSTEM.......................................................................................................... 9314
Service Precaution...................................................................................................................... 9315
General Description..................................................................................................................... 9315
PIN ASSIGNMENT TABLE................................................................................................................ 9317
System Components................................................................................................................... 9317
Control Unit........................................................................................................................ 9317
Actuator............................................................................................................................ 9317
Adjustable Damping Force Shock Absorber............................................................................................. 9317
Warning Lamp........................................................................................................................ 9317
Vertical G-Sensor................................................................................................................... 9318
Horizontal G-Sensor................................................................................................................. 9318
Acronyms and Abbreviations.......................................................................................................... 9318
General Diagnosis....................................................................................................................... 9318
General Information................................................................................................................. 9318
Service Precautions................................................................................................................. 9318
Computer System Service Precautions................................................................................................. 9318
General Service Precautions......................................................................................................... 9318
Parts Handling...................................................................................................................... 9318
FLASHING CODES...................................................................................................................... 9319
CLEAR DTC........................................................................................................................... 9320
INTERMITTENT CONDITIONS............................................................................................................. 9321
BULB CHECK.......................................................................................................................... 9321
DTC CHECK........................................................................................................................... 9321
Basic Diagnosis Flow................................................................................................................ 9322
Circuit Diagram..................................................................................................................... 9323
Parts Location...................................................................................................................... 9326
Connector List...................................................................................................................... 9327
Diagnostic Trouble Code (DTC) Identification........................................................................................ 9329
DTC2 Actuator Coil Over Current......................................................................................................... 9330
Circuit Description................................................................................................................. 9330
Diagnostic Aids..................................................................................................................... 9330
DTC2 Actuator Coil Over Current..................................................................................................... 9330
DTC3 Actuator Coil/Position Sensor Open Circuit or Short................................................................................ 9332
Circuit Description................................................................................................................. 9332
Diagnostic Aids..................................................................................................................... 9332
DTC3 Actuator Coil/Position Sensor Open Circuit or Short............................................................................ 9332
DTC4 G-Sensor Open Circuit or Short..................................................................................................... 9335
Circuit Description................................................................................................................. 9335
Diagnostic Aids..................................................................................................................... 9335
DTC4 G-Sensor Open Circuit or Short................................................................................................. 9335
DTC5 Vehicle Speed Sensor Open Circuit or Short......................................................................................... 9336
Circuit Description................................................................................................................. 9336
Diagnostic Aids..................................................................................................................... 9336
DTC5 Vehicle Speed Sensor Open Circuit or Short..................................................................................... 9337
DTC6 Stop Lamp Switch Open Circuit or Short............................................................................................. 9338
Circuit Description................................................................................................................. 9338
Diagnostic Aids..................................................................................................................... 9338
DTC6 Stop Lamp Switch Open Circuit or Short......................................................................................... 9338
DTC7 Engine Speed Signal Open Circuit or Short.......................................................................................... 9340
Circuit Description................................................................................................................. 9340
Diagnostic Aids..................................................................................................................... 9340
DTC7 Engine Speed Signal Open Circuit or Short...................................................................................... 9340
DTC9 Control Unit Abnormality....................................................................................................... 9341
DTC9-1 Control Unit Blown Fuse for FR Actuator...................................................................................... 9341
DTC9-2 Control Unit Blown Fuse for FL Actuator...................................................................................... 9342
DTC9-3 Control Unit Blown Fuse for RR Shock Absorber................................................................................ 9343
DTC9-4 Control Unit Blown Fuse for RL Shock Absorber................................................................................ 9344
Control Unit........................................................................................................................ 9345
Control Unit and Associated Parts................................................................................................... 9345
Removal............................................................................................................................. 9345
Installation........................................................................................................................ 9346
Front Actuator...................................................................................................................... 9347
Front Actuator and Associated Parts................................................................................................. 9347
Removal............................................................................................................................. 9348
View B.............................................................................................................................. 9348
Inspection and Repair............................................................................................................... 9348
Installation........................................................................................................................ 9348
Rear Shock Absorber................................................................................................................. 9349
Rear Shock Absorber and Associated Parts............................................................................................ 9349
Removal............................................................................................................................. 9350
Inspection and Repair............................................................................................................... 9350
Installation........................................................................................................................ 9350
Sec.4 DRIVELINE/AXLE.......................................................................................................................... 9479
4A1 DIFFERENTIAL (FRONT).................................................................................................................. 9351
Service Precaution...................................................................................................................... 9351
Front Drive Axle........................................................................................................................ 9352
Diagnosis............................................................................................................................... 9352
Pinion Shaft Oil Seal................................................................................................................... 9353
Pinion Shaft Oil Seal and Associated Parts.......................................................................................... 9353
Removal............................................................................................................................. 9353
Inspection and Repair............................................................................................................... 9354
Installation........................................................................................................................ 9354
Front Drive Axle Assembly............................................................................................................... 9355
Front Drive Axle Assembly and Associated Parts...................................................................................... 9355
Removal............................................................................................................................. 9356
Installation........................................................................................................................ 9356
Differential Assembly................................................................................................................... 9358
Disassembled View................................................................................................................... 9358
Disassembly......................................................................................................................... 9359
Reassembly.......................................................................................................................... 9361
Differential Cage Assembly.............................................................................................................. 9369
Disassembled View................................................................................................................... 9369
Disassembly......................................................................................................................... 9369
Inspection and Repair............................................................................................................... 9370
Reassembly.......................................................................................................................... 9370
Main Data and Specifications............................................................................................................ 9372
Special Tools........................................................................................................................... 9375
4A2 DIFFERENTIAL (REAR)................................................................................................................... 9377
Service Precaution...................................................................................................................... 9377
General Description..................................................................................................................... 9378
Diagnosis............................................................................................................................... 9379
Axle Housing............................................................................................................................ 9381
Axle Housing and Associated Parts................................................................................................... 9381
Removal............................................................................................................................. 9381
Installation........................................................................................................................ 9383
Axle Shaft, Oil Seal and Bearing........................................................................................................ 9383
Axle Shaft and Associated Parts..................................................................................................... 9383
Removal............................................................................................................................. 9384
Inspection.......................................................................................................................... 9384
Installation........................................................................................................................ 9384
Pinion Oil Seal......................................................................................................................... 9386
Pinion Oil Seal and Associated Parts................................................................................................ 9386
Removal............................................................................................................................. 9386
Inspection and Repair............................................................................................................... 9387
Installation........................................................................................................................ 9387
Differential Assembly................................................................................................................... 9389
Disassembled View................................................................................................................... 9389
Inspecting the Axle Before Disassembly.............................................................................................. 9390
Disassembly......................................................................................................................... 9390
Inspection and Repair............................................................................................................... 9392
Reassembly.......................................................................................................................... 9392
Side Bearing Preload Adjustment..................................................................................................... 9396
Pinion Installation................................................................................................................. 9397
Determination of Backlash & Preload Shims........................................................................................... 9398
Backlash Adjustment................................................................................................................. 9399
Gear Tooth Pattern Check............................................................................................................ 9399
Adjustments Affecting Tooth Contact................................................................................................. 9400
Differential Case Assembly.............................................................................................................. 9401
Disassembled View................................................................................................................... 9401
Disassembly......................................................................................................................... 9402
Inspection and Repair............................................................................................................... 9402
Reassembly.......................................................................................................................... 9402
Limited Slip Differential Assembly...................................................................................................... 9403
Disassembled View................................................................................................................... 9403
Disassembly......................................................................................................................... 9403
Inspection and Repair............................................................................................................... 9405
Reassembly.......................................................................................................................... 9405
Main Data And Specifications............................................................................................................ 9407
Special Tools........................................................................................................................... 9409
4B DRIVELINE CONTROL SYSTEM.............................................................................................................. 9411
Service Precaution...................................................................................................................... 9411
Shift On The Fly System................................................................................................................. 9412
Outline of Shift on The Fly System...................................................................................................... 9412
Functions of Indicator Lamp............................................................................................................. 9416
Diagnosis............................................................................................................................... 9417
Shift On The Fly Electrical Equipment................................................................................................... 9427
Axle Shaft Connection and Disconnection................................................................................................. 9427
4WD Control Unit........................................................................................................................ 9430
4WD Control Unit Associated Parts................................................................................................... 9430
Removal............................................................................................................................. 9430
Installation........................................................................................................................ 9431
Shift On The Fly Controller............................................................................................................. 9432
Shift On The Fly Controller and Associated Parts.................................................................................... 9432
Removal............................................................................................................................. 9432
Installation........................................................................................................................ 9432
4C DRIVE SHAFT SYSTEM.................................................................................................................... 9433
Service Precaution...................................................................................................................... 9433
General Description..................................................................................................................... 9434
Diagnosis............................................................................................................................... 9434
Front Hub and Disc (2WD Model).......................................................................................................... 9435
Disassembled View................................................................................................................... 9435
Disassembly......................................................................................................................... 9435
Inspection and Repair............................................................................................................... 9436
Reassembly.......................................................................................................................... 9437
Front Hub and Disc (4WD Model).......................................................................................................... 9440
Disassembled View................................................................................................................... 9440
Disassembly......................................................................................................................... 9440
Inspection and Repair............................................................................................................... 9441
Reassembly.......................................................................................................................... 9442
Front Drive Shaft Joint................................................................................................................. 9445
Front Drive Shaft Joints Replacement................................................................................................ 9445
Front Axle Drive Shaft.................................................................................................................. 9446
Front Axle Drive Shaft and Associated Parts......................................................................................... 9446
Disassembly......................................................................................................................... 9447
Inspection And Repair............................................................................................................... 9448
Bushing Replacement................................................................................................................. 9448
Reassembly.......................................................................................................................... 9448
Shift On The Fly System................................................................................................................. 9451
Shift On The Fly System and Associated Parts........................................................................................ 9451
Disassembly......................................................................................................................... 9451
Inspection And Repair............................................................................................................... 9453
Reassembly.......................................................................................................................... 9455
Main Data and Specifications........................................................................................................ 9458
Special Tools....................................................................................................................... 9460
Propeller Shaft......................................................................................................................... 9461
General Description..................................................................................................................... 9461
Universal Joint......................................................................................................................... 9462
Diagnosis of Propeller Shaft and Universal Joint........................................................................................ 9463
Front Propeller Shaft................................................................................................................... 9464
Front Propeller Shaft and Associated Parts.......................................................................................... 9464
Removal............................................................................................................................. 9464
Installation........................................................................................................................ 9464
Disassembly......................................................................................................................... 9465
Universal Joint Disassembly......................................................................................................... 9466
Inspection and Repair............................................................................................................... 9467
Universal Joint Reassembly.......................................................................................................... 9468
Reassembly.......................................................................................................................... 9469
Main Data and Specifications........................................................................................................ 9470
Rear Propeller Shaft.................................................................................................................... 9471
Rear Propeller Shaft and Associated Parts........................................................................................... 9471
Removal............................................................................................................................. 9471
Installation........................................................................................................................ 9471
Slip Joint Disassembly.............................................................................................................. 9472
Universal Joint Disassembly......................................................................................................... 9473
Inspection.......................................................................................................................... 9475
Universal Joint Reassembly.......................................................................................................... 9476
Slip Joint Reassembly............................................................................................................... 9477
Main Data and Specifications........................................................................................................ 9478
4D TRANSFER CASE......................................................................................................................... 9479
Service Precaution...................................................................................................................... 9479
General Description..................................................................................................................... 9480
Transfer Rear Oil Seal.................................................................................................................. 9482
Transfer Rear Oil Seal and Associated Parts......................................................................................... 9482
Removal............................................................................................................................. 9482
Installation........................................................................................................................ 9482
Transfer Case Assembly (A/T)............................................................................................................ 9484
Transfer Case Assembly (A/T) and Associated Parts................................................................................... 9484
Removal............................................................................................................................. 9484
Installation........................................................................................................................ 9486
Transfer Rear Case Assembly (A/T)....................................................................................................... 9489
Transfer Rear Case Assembly (A/T) and Associated Parts.............................................................................. 9489
Removal............................................................................................................................. 9489
Installation........................................................................................................................ 9491
Transfer Rear Cover Assembly........................................................................................................ 9494
Disassembly......................................................................................................................... 9494
Inspection and Repair............................................................................................................... 9495
Reassembly.......................................................................................................................... 9495
Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)........................................................................... 9497
Disassembled View................................................................................................................... 9497
Disassembly......................................................................................................................... 9498
Inspection and Repair............................................................................................................... 9499
Reassembly.......................................................................................................................... 9499
Transfer Case Assembly.................................................................................................................. 9501
Disassembled View................................................................................................................... 9501
Disassembly......................................................................................................................... 9502
Inspection and Repair............................................................................................................... 9505
Reassembly.......................................................................................................................... 9508
Main Data and Specifications............................................................................................................ 9515
Special Tools........................................................................................................................... 9518
Sec.5 BRAKES.................................................................................................................................. 9519
5A BRAKE CONTROL SYSTEM.................................................................................................................. 9519
Service Precaution...................................................................................................................... 9520
General Description..................................................................................................................... 9521
Functional Description.............................................................................................................. 9522
System Components................................................................................................................... 9528
Electronic Hydraulic Control Unit (EHCU)............................................................................................ 9528
ABS Warning Light................................................................................................................... 9528
Wheel Speed Sensor.................................................................................................................. 9528
G-Sensor............................................................................................................................ 9528
Normal and Anti-lock Braking........................................................................................................ 9528
Brake Pedal Travel.................................................................................................................. 9528
Acronyms and Abbreviations.......................................................................................................... 9528
General Diagnosis....................................................................................................................... 9529
General Information................................................................................................................. 9529
ABS Service Precautions............................................................................................................. 9529
Computer System Service Precautions................................................................................................. 9529
General Service Precautions......................................................................................................... 9529
Note on Intermittents............................................................................................................... 9529
Test Driving ABS Complaint Vehicles................................................................................................. 9530
"ABS" Warning Light................................................................................................................. 9530
Normal Operation.................................................................................................................... 9530
Tech 2 Scan Tool.................................................................................................................... 9531
DATA LIST........................................................................................................................... 9534
ACTUATOR TEST....................................................................................................................... 9535
Tech 2 Service Bleed................................................................................................................ 9539
Basic Diagnostic Flow Chart......................................................................................................... 9540
Basic Inspection Procedure.......................................................................................................... 9541
EHCU Connector Pin-out Checks........................................................................................................... 9542
Circuit Diagram..................................................................................................................... 9543
Connector List...................................................................................................................... 9546
Part Location....................................................................................................................... 9547
Symptom Diagnosis....................................................................................................................... 9548
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate...................................................................... 9548
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................ 9549
Chart A-2 Uneven Braking Occurs While ABS Works..................................................................................... 9549
Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2)....................................................................... 9549
Chart A-3, TA-3 The Wheels Are Locked............................................................................................... 9550
Chart A-4 Brake Pedal Feed Is Abnormal.............................................................................................. 9551
Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................ 9552
Diagnostic Trouble Codes................................................................................................................ 9553
Diagnosis By "ABS" Warning Light Illumination Pattern................................................................................... 9555
Diagnostic Trouble Codes (DTCs)..................................................................................................... 9556
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................ 9558
Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial communications))....................................... 9559
Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial communications))................................... 9559
Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications)).................................................. 9559
Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications))............................................. 9560
Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications)).............................................. 9560
Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications))................................................. 9560
Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial communications)), 4WD State Input Signal .... 9561
Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial communications))............................................ 9561
Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial communications))........................... 9562
Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial communications))................................ 9562
Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash out) / C0241, C0243 (Serial communications))........................... 9563
Chart B-14 FR Dump Solenoid Coil Failure (DTC 44(Flash out) / C0242, C0244 (Serial communications))................................. 9563
Chart B-15 Rear Isolation Solenoid Coil Failure (DTC 45 (Flash out) / C0251, C0253 (Serial communications))......................... 9563
Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash out) / C0252, C0254 (Serial communications)).............................. 9564
Chart B-17 FL Speed Sensor Open or Shorted (DTC 51 (Flash out) / C0225 (Serial communications))..................................... 9564
Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash out) / C0221 (Serial communications))..................................... 9565
Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash out) / C0235 (Serial communications))................................... 9566
Chart B-20 FL Speed Sensor Missing (DTC 61 (Flash out) / C0226, C0227 (Serial communications))...................................... 9567
Chart B-21 FR Speed Sensor Missing (DTC 62 (Flash out) / C0222, C0223 (Serial communications))...................................... 9568
Chart B-22 Rear Speed Sensor Missing (DTC 63 (Flash out) / C0236, C0237 (Serial communications)).................................... 9569
Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal (DTC 64 (Flash out) / C0229 (Serial communications)).................. 9570
Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash out) / C0238 (Serial communications))....................................... 9571
Unit Inspection Procedure............................................................................................................... 9572
Chart C-1-1 FL Sensor Output Inspection Procedure................................................................................... 9572
Chart C-1-2 FR Sensor Output Inspection Procedure................................................................................... 9573
Chart C-1-3 Rear Sensor Output Inspection Procedure................................................................................. 9573
Chart TC-1 Sensor Output Inspection Procedure....................................................................................... 9574
Special Tools........................................................................................................................... 9575
5B ANTI-LOCK BRAKE SYSTEM................................................................................................................ 9576
Service Precaution...................................................................................................................... 9576
Electronic Hydraulic Control Unit....................................................................................................... 9577
Electronic Hydraulic Control Unit and Associated Parts.............................................................................. 9577
Removal............................................................................................................................. 9577
Disassembled View................................................................................................................... 9578
Disassembly......................................................................................................................... 9578
Reassembly.......................................................................................................................... 9578
Installation........................................................................................................................ 9578
Front Wheel Speed Sensor................................................................................................................ 9579
Front Wheel Speed Sensor and Associated Parts....................................................................................... 9579
Removal............................................................................................................................. 9579
Inspection and Repair............................................................................................................... 9579
Installation........................................................................................................................ 9579
Rear Wheel Speed Sensor................................................................................................................. 9580
Removal............................................................................................................................. 9580
Inspection and Repair............................................................................................................... 9580
Installation........................................................................................................................ 9580
5C POWER-ASSISTED BRAKE SYSTEM........................................................................................................... 9581
Service Precaution...................................................................................................................... 9582
General Description..................................................................................................................... 9582
Diagnosis............................................................................................................................... 9586
General Diagnosis....................................................................................................................... 9587
Hydraulic Brakes........................................................................................................................ 9590
Filling Master Cylinder Reservoir................................................................................................... 9590
Deterioration of Brake Fluid........................................................................................................ 9590
Leakage of Brake Fluid.............................................................................................................. 9590
Bleeding Brake Hydraulic System..................................................................................................... 9590
Flushing Brake Hydraulic System..................................................................................................... 9591
Brake Pipes and Hoses............................................................................................................... 9591
Brake Hose Inspection............................................................................................................... 9591
Front Caliper Brake Hose................................................................................................................ 9592
Front Caliper Brake Hose and Associated Parts....................................................................................... 9592
Removal............................................................................................................................. 9592
Installation........................................................................................................................ 9592
Rear Axle Brake Hose.................................................................................................................... 9593
Rear Axle Brake Hose and Associated Parts........................................................................................... 9593
Removal............................................................................................................................. 9593
Installation........................................................................................................................ 9593
Brake Pipe.............................................................................................................................. 9594
Removal............................................................................................................................. 9594
Installation........................................................................................................................ 9594
P & B (Proportioning and Bypass) Valve.................................................................................................. 9595
P & B (Proportioning and Bypass) Valve Sectional View............................................................................... 9595
Removal............................................................................................................................. 9595
Installation........................................................................................................................ 9595
Main Data and Specifications............................................................................................................ 9596
Brake Pedal............................................................................................................................. 9597
Checking Pedal Height............................................................................................................... 9597
Checking Pedal Travel............................................................................................................... 9597
Brake Pedal and Associated Parts.................................................................................................... 9598
Removal............................................................................................................................. 9598
Installation........................................................................................................................ 9598
Stoplight Switch........................................................................................................................ 9599
Parts Location...................................................................................................................... 9599
Removal............................................................................................................................. 9599
Installation........................................................................................................................ 9599
Main Data and Specifications............................................................................................................ 9600
Fluid Reservoir Tank.................................................................................................................... 9601
Fluid Reservoir Tank and Associated Parts........................................................................................... 9601
Removal............................................................................................................................. 9601
Installation........................................................................................................................ 9601
Master Cylinder Assembly................................................................................................................ 9602
Master Cylinder Assembly and Associated Parts....................................................................................... 9602
Removal............................................................................................................................. 9602
Inspection and Repair............................................................................................................... 9602
Installation........................................................................................................................ 9603
Main Data and Specifications............................................................................................................ 9604
Special Tools........................................................................................................................... 9604
Vacuum Booster Assembly................................................................................................................. 9605
Vacuum Booster Assembly and Associated Parts........................................................................................ 9605
Removal............................................................................................................................. 9605
Inspection and Repair............................................................................................................... 9605
Installation........................................................................................................................ 9606
Exterior Components..................................................................................................................... 9608
Exterior Components and Associated Parts............................................................................................ 9608
Removal............................................................................................................................. 9608
Inspection and Repair............................................................................................................... 9609
Installation........................................................................................................................ 9609
Vacuum Booster Overhaul................................................................................................................. 9609
Vacuum Booster...................................................................................................................... 9609
Main Data and Specifications............................................................................................................ 9610
Special Tools........................................................................................................................... 9611
Front Disc Brake Pads................................................................................................................... 9612
Front Disc Brake Pads Inspection.................................................................................................... 9612
Front Disc Brake Pads and Associated Parts.......................................................................................... 9612
Removal............................................................................................................................. 9613
Installation........................................................................................................................ 9613
Front Disc Brake Rotor.................................................................................................................. 9615
Inspection.......................................................................................................................... 9615
Replacing Brake Rotors.............................................................................................................. 9615
Refinishing Brake Rotors............................................................................................................ 9615
Front Disc Brake Caliper Assembly....................................................................................................... 9616
Front Disc Brake Caliper Assembly and Associated Parts.............................................................................. 9616
Removal............................................................................................................................. 9617
Installation........................................................................................................................ 9617
Front Disc Brake Caliper................................................................................................................ 9619
Front Disc Brake Caliper Disassembled View.......................................................................................... 9619
Disassembly......................................................................................................................... 9619
Inspection and Repair............................................................................................................... 9620
Reassembly.......................................................................................................................... 9620
Main Data and Specifications............................................................................................................ 9622
Rear Disc Brake Pads (4 × 4 Model)...................................................................................................... 9623
Brake Pads Inspection............................................................................................................... 9623
Brake Pads and Associated Parts..................................................................................................... 9623
Removal............................................................................................................................. 9624
Installation........................................................................................................................ 9624
Rear Disc Brake Rotor (4 × 4 Model)..................................................................................................... 9626
Inspection.......................................................................................................................... 9626
Replacing Brake Rotors.............................................................................................................. 9626
Refinishing Brake Rotors............................................................................................................ 9626
Rear Drum (In Disc) Inside Diameter Check........................................................................................... 9627
Rear Disc Brake Caliper Assembly (4 × 4 Model).......................................................................................... 9628
Rear Disc Brake Caliper Assembly and Associated Parts............................................................................... 9628
Removal............................................................................................................................. 9628
Installation........................................................................................................................ 9629
Rear Disc Brake Caliper (4 × 4 Model)................................................................................................... 9630
Rear Disc Brake Caliper Disassembled View........................................................................................... 9630
Disassembly......................................................................................................................... 9631
Inspection and Repair............................................................................................................... 9631
Reassembly.......................................................................................................................... 9631
Main Data and Specifications (4 × 4 Model).............................................................................................. 9633
Brake Lining............................................................................................................................ 9634
Brake Lining and Associated Parts................................................................................................... 9634
Removal............................................................................................................................. 9634
Brake Lining Inspection............................................................................................................. 9635
Installation........................................................................................................................ 9635
Drum Brake Adjustment (4 × 2 Model)................................................................................................. 9636
Servicing The Brake Drum............................................................................................................ 9636
Wheel Cylinder Assembly (4 × 2 Model)................................................................................................... 9637
Wheel Cylinder Assembly and Associated Parts........................................................................................ 9637
Removal............................................................................................................................. 9637
Installation........................................................................................................................ 9637
Disassembled View................................................................................................................... 9638
Disassembly......................................................................................................................... 9638
Inspection and Repair............................................................................................................... 9638
Reassembly.......................................................................................................................... 9638
Main Data and Specifications............................................................................................................ 9640
5D1 PARKING BRAKE SYSTEM (4x4 Model)...................................................................................................... 9641
Service Precaution...................................................................................................................... 9641
General Description..................................................................................................................... 9641
Operation............................................................................................................................... 9642
Parking Brake Lever and Front Cable..................................................................................................... 9643
Parking Brake Lever Assembly and Associated Parts................................................................................... 9643
Removal............................................................................................................................. 9643
Installation........................................................................................................................ 9643
Parking Brake Rear Cable................................................................................................................ 9644
Parking Brake Rear Cable and Associated Parts....................................................................................... 9644
Removal............................................................................................................................. 9645
Installation........................................................................................................................ 9645
Inspection and Repair............................................................................................................... 9646
Parking Brake Adjustment............................................................................................................ 9646
Main Data and Specifications............................................................................................................ 9647
5D2 PARKING BRAKE SYSTEM (4x2 Model)...................................................................................................... 9648
Service Precaution...................................................................................................................... 9648
General Description..................................................................................................................... 9648
Parking Brake Lever..................................................................................................................... 9649
Parking Brake Lever Assembly and Associated Parts................................................................................... 9649
Removal............................................................................................................................. 9649
Installation........................................................................................................................ 9649
Parking Brake Rear Cable................................................................................................................ 9650
Parking Brake Rear Cable and Associated Parts....................................................................................... 9650
Removal............................................................................................................................. 9651
Installation........................................................................................................................ 9651
Parking Brake Adjustment............................................................................................................ 9651
Main Data and Specifications............................................................................................................ 9652
Sec.6 ENGINE.................................................................................................................................. 9653
X22SE 2.2L ENGINE........................................................................................................................... 9653
6A ENGINE MECHANICAL.................................................................................................................. 9653
Service Precaution.................................................................................................................. 9654
General Description................................................................................................................. 9654
Engine Diagnosis.................................................................................................................... 9655
Cylinder Head Cover................................................................................................................. 9668
Removal......................................................................................................................... 9668
Installation.................................................................................................................... 9669
Exhaust Manifold.................................................................................................................... 9670
Removal......................................................................................................................... 9670
Installation.................................................................................................................... 9670
Crankshaft Pulley................................................................................................................... 9671
Removal......................................................................................................................... 9671
Installation.................................................................................................................... 9671
Intake Manifold..................................................................................................................... 9672
Removal......................................................................................................................... 9672
Installation.................................................................................................................... 9673
Cylinder Head Assembly.............................................................................................................. 9674
Removal......................................................................................................................... 9674
Installation.................................................................................................................... 9676
Timing Belt......................................................................................................................... 9680
Removal......................................................................................................................... 9680
Installation.................................................................................................................... 9681
Camshaft............................................................................................................................ 9684
Removal......................................................................................................................... 9684
Installation.................................................................................................................... 9685
Engine Assembly..................................................................................................................... 9687
Removal......................................................................................................................... 9688
Installation.................................................................................................................... 9689
Cylinder Head....................................................................................................................... 9691
Cylinder Head and Associated Parts.............................................................................................. 9691
Disassembly..................................................................................................................... 9691
Inspection and Repair........................................................................................................... 9692
Reassembly...................................................................................................................... 9693
Valve Spring, Valve, Valve Guide.................................................................................................... 9694
Valve Spring, Valve, Valve Guide and Associated Parts........................................................................... 9694
Disassembly..................................................................................................................... 9694
Inspection and Repair........................................................................................................... 9695
Reassembly...................................................................................................................... 9696
Camshaft............................................................................................................................ 9697
Camshaft and Associated Parts................................................................................................... 9697
Disassembly..................................................................................................................... 9697
Reassembly...................................................................................................................... 9698
Crankshaft.......................................................................................................................... 9699
Crankshaft and Associated Parts................................................................................................. 9699
Disassembly..................................................................................................................... 9699
Inspection and Repair........................................................................................................... 9700
Inspection and Repair........................................................................................................... 9701
Reassembly...................................................................................................................... 9702
Piston and Connecting Rod........................................................................................................... 9705
Piston, Connecting Rod and Associate Parts...................................................................................... 9705
Disassembly..................................................................................................................... 9705
Inspection and Repair........................................................................................................... 9706
Reassembly...................................................................................................................... 9708
Cylinder Block...................................................................................................................... 9709
Cylinder Block and Associated Parts............................................................................................. 9709
Disassembly..................................................................................................................... 9710
Inspection and Repair........................................................................................................... 9710
Reassembly...................................................................................................................... 9711
Cylinder Head Cover................................................................................................................. 9712
Cylinder Head Cover and Associated parts........................................................................................ 9712
Removal......................................................................................................................... 9713
Installation.................................................................................................................... 9713
Balance Unit Assembly............................................................................................................... 9715
Balance Unit Assembly Associated Parts.......................................................................................... 9715
Disassembly..................................................................................................................... 9716
Adjustment...................................................................................................................... 9716
Reassembly...................................................................................................................... 9718
Main Data and Specifications........................................................................................................ 9720
Special Tools....................................................................................................................... 9725
6B ENGINE COOLING..................................................................................................................... 9726
Service Precaution.................................................................................................................. 9726
General Description................................................................................................................. 9727
Diagnosis........................................................................................................................... 9729
Draining and Refilling Cooling System............................................................................................... 9729
Water Pump.......................................................................................................................... 9730
Water Pump and Associated Parts..................................................................................................... 9730
Removal......................................................................................................................... 9730
Inspection...................................................................................................................... 9730
Installation.................................................................................................................... 9730
Thermostat.......................................................................................................................... 9731
Removal......................................................................................................................... 9731
Inspection...................................................................................................................... 9731
Installation.................................................................................................................... 9731
Radiator............................................................................................................................ 9732
Radiator and Associated Parts................................................................................................... 9732
Removal......................................................................................................................... 9732
Inspection...................................................................................................................... 9733
Installation.................................................................................................................... 9733
Main Data and Specifications........................................................................................................ 9734
Special Tool........................................................................................................................ 9734
6C ENGINE FUEL........................................................................................................................ 9735
Service Precaution.................................................................................................................. 9735
General Description................................................................................................................. 9736
Fuel Metering....................................................................................................................... 9737
Fuel Filter......................................................................................................................... 9738
Fuel Filter and Associated Parts................................................................................................ 9738
Removal......................................................................................................................... 9738
Inspection...................................................................................................................... 9738
Installation.................................................................................................................... 9738
Inspection...................................................................................................................... 9738
In-Tank Fuel Filter............................................................................................................. 9738
Fuel Pump Flow Test............................................................................................................. 9739
Fuel Pump........................................................................................................................... 9740
Fuel Pump and Associated Parts.................................................................................................. 9740
Removal......................................................................................................................... 9740
Installation.................................................................................................................... 9740
Fuel Tube / Quick-Connector Fittings................................................................................................ 9741
Precautions..................................................................................................................... 9741
Cautions During Work............................................................................................................ 9741
Removal......................................................................................................................... 9741
Reuse of Quick-Connector........................................................................................................ 9743
Assembling Advice............................................................................................................... 9743
Fuel Pump Relay..................................................................................................................... 9744
General Description............................................................................................................. 9744
Fuel Tank........................................................................................................................... 9744
Fuel Tank and Associated Parts.................................................................................................. 9744
Removal......................................................................................................................... 9745
Installation.................................................................................................................... 9745
Fuel Gage Unit...................................................................................................................... 9745
Removal and Installation........................................................................................................ 9745
Fuel Filler Cap..................................................................................................................... 9746
General Description............................................................................................................. 9746
Inspection...................................................................................................................... 9746
Main Data and Specifications........................................................................................................ 9747
Special Tool........................................................................................................................ 9747
6D1 ENGINE ELECTRICAL.................................................................................................................. 9748
Service Precaution.................................................................................................................. 9748
Battery............................................................................................................................. 9749
General Description............................................................................................................. 9749
Diagnosis....................................................................................................................... 9749
Battery Charging................................................................................................................ 9750
Jump Starting................................................................................................................... 9750
Battery Removal................................................................................................................. 9751
Battery Installation............................................................................................................ 9751
Main Data and Specifications........................................................................................................ 9752
6D2 IGNITION SYSTEM.................................................................................................................... 9753
Service Precaution.................................................................................................................. 9753
General Description................................................................................................................. 9753
Diagnosis........................................................................................................................... 9753
Ignition Module..................................................................................................................... 9754
Removal......................................................................................................................... 9754
Installation.................................................................................................................... 9754
Spark Plug.......................................................................................................................... 9754
Removal......................................................................................................................... 9754
Inspection and Repair........................................................................................................... 9754
Installation.................................................................................................................... 9755
Crankshaft Angle Sensor............................................................................................................. 9755
Removal......................................................................................................................... 9755
Installation.................................................................................................................... 9755
Main Data and Specifications........................................................................................................ 9756
6D3 STARTING AND CHARGING SYSTEM....................................................................................................... 9757
Service Precaution.................................................................................................................. 9757
Starting System..................................................................................................................... 9758
General Description............................................................................................................. 9758
Diagnosis....................................................................................................................... 9758
Starter............................................................................................................................. 9759
Removal......................................................................................................................... 9759
Installation.................................................................................................................... 9759
Disassembled View............................................................................................................... 9760
Inspection and Repair........................................................................................................... 9761
Characteristic Test............................................................................................................. 9762
Charging System..................................................................................................................... 9763
General Description................................................................................................................. 9763
General On-Vehicle Inspection....................................................................................................... 9763
Generator........................................................................................................................... 9764
Removal......................................................................................................................... 9764
Inspection...................................................................................................................... 9764
Installation.................................................................................................................... 9765
Disassembly..................................................................................................................... 9765
Inspection and Repair........................................................................................................... 9767
Reassembly...................................................................................................................... 9769
Main Data and Specifications........................................................................................................ 9770
6E1 2.2L ENGINE DRIVEABILITY AND EMISSIONS............................................................................................. 9771
SPECIFICATIONS...................................................................................................................... 9776
TIGHTENING SPECIFICATIONS....................................................................................................... 9776
DIAGRAMS AND SCHEMATICS............................................................................................................. 9777
PCM WIRING DIAGRAM (1 of 10).................................................................................................... 9777
PCM WIRING DIAGRAM (2 of 10).................................................................................................... 9778
PCM WIRING DIAGRAM (3 of 10).................................................................................................... 9779
PCM WIRING DIAGRAM (4 of 10).................................................................................................... 9780
PCM WIRING DIAGRAM (5 of 10).................................................................................................... 9781
PCM WIRING DIAGRAM (6 of 10).................................................................................................... 9782
PCM WIRING DIAGRAM (7 of 10).................................................................................................... 9783
PCM WIRING DIAGRAM (8 of 10).................................................................................................... 9784
PCM WIRING DIAGRAM (9 of 10).................................................................................................... 9785
PCM WIRING DIAGRAM (10 of 10)................................................................................................... 9786
PCM PINOUTS......................................................................................................................... 9787
PCM Pinout Table, 32-Pin Red Connector - Row "A"................................................................................ 9787
PCM Pinout Table, 32-Pin Red Connector - Row "B"................................................................................ 9788
PCM Pinout Table, 32-Pin White Connector - Row "C".............................................................................. 9789
PCM Pinout Table, 32-Pin White Connector - Row "D".............................................................................. 9790
PCM Pinout Table, 32-Pin White Connector - Row "E".............................................................................. 9791
PCM Pinout Table, 32-Pin White Connector - Row "F".............................................................................. 9792
COMPONENT LOCATOR................................................................................................................... 9793
Engine Component Locator Table.................................................................................................. 9795
Undercarriage Component Locator Table........................................................................................... 9795
Fuse And Relay Panel (Underhood Electrical Center).............................................................................. 9795
DIAGNOSIS Strategy-Based Diagnostics................................................................................................ 9797
Strategy-Based Diagnostics...................................................................................................... 9797
DTC Stored...................................................................................................................... 9797
No DTC.......................................................................................................................... 9797
No Matching Symptom............................................................................................................. 9797
Intermittents................................................................................................................... 9797
No Trouble Found................................................................................................................ 9797
Verifying Vehicle Repair........................................................................................................ 9797
GENERAL SERVICE INFORMATION......................................................................................................... 9798
OBD II Serviceability Issues.................................................................................................... 9798
Emissions Control Information Label............................................................................................. 9798
Maintenance Schedule............................................................................................................ 9799
Visual/Physical Engine Compartment Inspection................................................................................... 9799
Basic Knowledge Of Tools Required............................................................................................... 9799
SERIAL DATA COMMUNICATIONS.......................................................................................................... 9799
Class II Serial Data Communications............................................................................................. 9799
ON-BOARD DIAGNOSTIC (OBD II)........................................................................................................ 9799
On-Board Diagnostic Tests....................................................................................................... 9799
Comprehensive Component Monitor Diagnostic Operation............................................................................ 9799
System Status And Drive Cycle For Satisfying Federal Inspection/Maintenance (I/M 240) Regulations............................... 9800
Common OBD II Terms............................................................................................................. 9800
The Diagnostic Executive........................................................................................................ 9801
DTC Types....................................................................................................................... 9802
Decimal/Binary/Hexadecimal Conversions.......................................................................................... 9803
Verifying Vehicle Repair........................................................................................................ 9803
Reading Diagnostic Trouble Codes Using A Tech 2 Scan Tool....................................................................... 9803
Tech 2 Features................................................................................................................. 9805
Getting Started................................................................................................................. 9805
Operating Procedure (Example)................................................................................................... 9806
DTC Modes....................................................................................................................... 9807
DTC Information Mode............................................................................................................ 9807
Miscellaneous Test.............................................................................................................. 9808
Lamps Test...................................................................................................................... 9808
Relays Test..................................................................................................................... 9809
EVAP Test....................................................................................................................... 9811
Idle Air Control System Test.................................................................................................... 9812
Fuel System Test................................................................................................................ 9814
EGR Control Test................................................................................................................ 9815
Injector Balance Test........................................................................................................... 9816
Plotting Snapshot Graph............................................................................................................. 9817
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information).................................................. 9818
Flow Chart for Snapshot Replay (Plotting Graph)................................................................................. 9819
PRIMARY SYSTEM-BASED DIAGNOSTICS.................................................................................................... 9820
Primary System-Based Diagnostics................................................................................................ 9820
Fuel Control Heated Oxygen Sensors.............................................................................................. 9820
HO2S Heater..................................................................................................................... 9820
Catalyst Monitor Heated Oxygen Sensors And Diagnostic Operation................................................................. 9820
MISFIRE MONITOR DIAGNOSTIC OPERATION................................................................................................ 9821
Misfire Monitor Diagnostic Operation............................................................................................ 9821
Misfire Counters................................................................................................................ 9821
FUEL TRIM SYSTEM MONITOR DIAGNOSTIC OPERATION....................................................................................... 9822
Fuel Trim System Monitor Diagnostic Operation................................................................................... 9822
Fuel Trim Cell Diagnostic Weights............................................................................................... 9822
ON-BOARD DIAGNOSTIC (OBD II) SYSTEM CHECK........................................................................................... 9823
A/C CLUTCH CONTROL CIRCUIT DIAGNOSIS................................................................................................ 9826
ELECTRONIC IGNITION SYSTEM DIAGNOSIS................................................................................................ 9829
EVAP CANISTER PURGE SOLENOID........................................................................................................ 9829
VISUAL CHECK OF THE EVAPORATIVE EMISSION CANISTER................................................................................... 9829
IDLE AIR CONTROL (IAC) VALVE........................................................................................................ 9829
FUEL SYSTEM PRESSURE TEST........................................................................................................... 9829
FUEL METERING SYSTEM CHECK.......................................................................................................... 9829
FUEL INJECTOR COIL TEST PROCEDURE AND FUEL INJECTOR BALANCE TEST PROCEDURE.......................................................... 9830
Test Description................................................................................................................ 9830
Injector Coil Test Procedure (Steps 1-6) And Injector Balance Test Procedure (Steps 7-11)....................................... 9831
POWERTRAIN CONTROL MODULE (PCM) DIAGNOSIS........................................................................................... 9835
MULTIPLE PCM INFORMATION SENSOR DTCs SET............................................................................................ 9835
EXHAUST GAS RECIRCULATION (EGR) DIAGNOSIS........................................................................................... 9839
ENGINE Tech 2 DATA DEFINITIONS AND RANGES........................................................................................... 9839
TYPICAL SCAN DATA VALUES............................................................................................................ 9842
NO MALFUNCTION INDICATOR LAMP (MIL)................................................................................................. 9846
MALFUNCTION INDICATOR LAMP (MIL) ON STEADY.......................................................................................... 9849
ENGINE CRANKS BUT WILL NOT RUN...................................................................................................... 9851
FUEL SYSTEM ELECTRICAL TEST......................................................................................................... 9857
FUEL SYSTEM DIAGNOSIS............................................................................................................... 9860
IDLE AIR CONTROL (IAC) SYSTEM CHECK................................................................................................. 9865
EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK........................................................................................ 9868
MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK....................................................................................... 9870
EVAPORATIVE (EVAP) EMISSIONS CANISTER PURGE VALVE SOLENOID CHECK.................................................................... 9872
Upshift Lamp System Check (Manual Transmission Only)................................................................................ 9875
PCM DIAGNOSTIC TROUBLE CODES........................................................................................................ 9878
DTC P0106 MANIFOLD ABSOLUTE PRESSURE................................................................................................ 9881
DTC P0107 MANIFOLD ABSOLUTE PRESSURE................................................................................................ 9884
DTC P0108 MANIFOLD ABSOLUTE PRESSURE................................................................................................ 9887
DTC P0112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW INPUT..................................................................... 9890
DTC P0113 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH INPUT.................................................................... 9893
DTC P0117 ENGINE COOLANT TEMPERATURE................................................................................................ 9896
DTC P0118 ENGINE COOLANT TEMPERATURE................................................................................................ 9899
DTC P0121 THROTTLE POSITION (TP) SENSOR............................................................................................. 9902
DTC P0122 THROTTLE POSITION (TP) SENSOR CIRCUITLOW INPUT............................................................................ 9905
DTC P0123 THROTTLE POSITION (TP) SENSOR............................................................................................. 9908
DTC P0125 INSUFFICIENT COOLANT TEMPERATURE.......................................................................................... 9911
DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE............................................................................................. 9914
DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE............................................................................................ 9917
DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE........................................................................................... 9920
DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY............................................................................................. 9923
DTC P0135 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 1).................................................................... 9926
DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)........................................................................... 9929
DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2).......................................................................... 9932
DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 2).................................................................. 9935
DTC P0141 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 2).................................................................... 9938
DTC P0171 SYSTEM TOO LEAN (BANK 1).................................................................................................. 9941
DTC P0172 SYSTEM TOO RICH (BANK 1).................................................................................................. 9945
DTC P0201 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 1................................................................................. 9949
DTC P0202 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 2................................................................................. 9952
DTC P0203 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 3................................................................................. 9955
DTC P0204 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 4................................................................................. 9958
DTC P0300 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED................................................................................. 9961
DTC P0301 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED................................................................................. 9965
DTC P0302 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED................................................................................. 9969
DTC P0303 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED................................................................................. 9973
DTC P0304 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED................................................................................. 9977
DTC P0325 KNOCK SENSOR (KS) CIRCUIT MALFUNCTION..................................................................................... 9981
DTC P0327 KNOCK SENSOR (KS) CIRCUIT LOW INPUT....................................................................................... 9984
DTC P0336 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT RANGE/PERFORMANCE................................................................ 9987
DTC P0337 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT LOW INPUT........................................................................ 9989
DTC P0341 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT RANGE/PERFORMANCE.................................................................. 9992
DTC P0342 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT LOW INPUT.......................................................................... 9995
DTC P0351 IGNITION COIL "A" PRIMARY/SECONDARY CIRCUIT MALFUNCTION................................................................... 9998
DTC P0352 IGNITION COIL "B" PRIMARY/SECONDARY CIRCUIT MALFUNCTION...................................................................10000
DTC P0401 EXHAUST GAS RECIRCULATION (EGR) FLOW INSUFFICIENT DETECTED................................................................10002
DTC P0402 EXHAUST GAS RECIRCULATION (EGR) EXCESSIVE FLOW DETECTED...................................................................10005
DTC P0404 EXHAUST GAS RECIRCULATION (EGR) CIRCUIT RANGE/PERFORMANCE.................................................................10007
DTC P0405 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT LOW........................................................................10011
DTC P0406 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT HIGH.......................................................................10014
DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD................................................................................10018
DTC P0440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM MALFUNCTION....................................................................10021
DTC P0442 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM SMALL LEAK DETECTED............................................................10026
DTC P0443 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION........................................10030
DTC P0446 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT CONTROL CIRCUIT MALFUNCTION...............................................10033
DTC P0449 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT VALVE/SOLENOID CIRCUIT MALFUNCTION........................................10037
DTC P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE...............................................................................10040
DTC P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT.......................................................................................10042
DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT......................................................................................10044
DTC P0480 COOLING FAN 1 CONTROL CIRCUIT MALFUNCTION.................................................................................10046
DTC P0481 COOLING FAN 2 CONTROL CIRCUIT MALFUNCTION.................................................................................10049
DTC P0502 VEHICLE SPEED SENSOR (VSS) CIRCUIT LOW INPUT..............................................................................10052
DTC P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED...............................................................................10054
DTC P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED..............................................................................10057
DTC P0532 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT LOW INPUT.........................................................................10060
DTC P0533 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT HIGH INPUT........................................................................10063
DTC P0562 SYSTEM VOLTAGE LOW........................................................................................................10066
DTC P0563 SYSTEM VOLTAGE HIGH.......................................................................................................10068
DTC P0601 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR............................................................................10070
DTC P1106 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE.................................................10072
DTC P1107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE..................................................10074
DTC P1111 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE.....................................................10076
DTC P1112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE......................................................10079
DTC P1114 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE..................................................10081
DTC P1115 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE.................................................10083
DTC P1121 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE...........................................................10086
DTC P1122 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE............................................................10088
DTC P1133 O2 SENSOR INSUFFICIENT SWITCHING (BANK 1 SENSOR 1)........................................................................10090
DTC P1134 O2 SENSOR TRANSITION TIME RATIO (BANK 1 SENSOR 1).........................................................................10093
DTC P1171 FUEL SYSTEM LEAN DURING ACCELERATION......................................................................................10096
DTC P1336 CRANKSHAFT POSITION SENSOR (CKP) SYSTEM VARIATION NOT LEARNED.............................................................10099
DTC P1380 ABS ROUGH ROAD SYSTEM FAULT...............................................................................................10102
DTC P1381 ABS ROUGH ROAD CLASS 2 SERIAL DATA FAULT..................................................................................10104
DTC 1404 EXHAUST GAS RECIRCULATION (EGR) CLOSED VALVE...............................................................................10107
DTC P1441 EVAPORATIVE EMISSION (EVAP) SYSTEM FLOW DURING NON-PURGE..................................................................10110
DTC P1546 A/C COMPRESSOR CLUTCH OUTPUT CIRCUIT MALFUNCTION .........................................................................10113
DTC P1625 PCM Unexpected Reset......................................................................................................10116
DTC P1627 PCM A/D CONVERSION MALFUNCTION............................................................................................10118
DTC P1635 5 VOLT REFERENCE VOLTAGE CIRCUIT MALFUNCTION..............................................................................10120
DTC P1640 ODM OUTPUT CIRCUIT FAULT..................................................................................................10122
SYMPTOM DIAGNOSIS...................................................................................................................10125
DEFAULT MATRIX TABLE................................................................................................................10148
Camshaft Position (CMP) Sensor......................................................................................................10151
Crankshaft Position (CKP) Sensor....................................................................................................10152
EEPROM..............................................................................................................................10154
Engine Coolant Temperature (ECT) Sensor.............................................................................................10154
Heated Oxygen Sensor (HO2S).........................................................................................................10155
Intake Air Temperature (IAT) Sensor.................................................................................................10156
Manifold Absolute Pressure (MAP) Sensor.............................................................................................10157
Malfunction Indicator Lamp (MIL)....................................................................................................10158
Powertrain Control Module (PCM).....................................................................................................10158
Throttle Position (TP) Sensor.......................................................................................................10161
Vehicle Speed Sensor (VSS)..........................................................................................................10162
Air Filter..........................................................................................................................10163
Idle Air Control (IAC) Valve........................................................................................................10164
Intake Air Duct.....................................................................................................................10165
Knock Sensor........................................................................................................................10167
Oil Pressure Switch.................................................................................................................10168
FUEL METERING SYSTEM Accelerator Cable Assembly.....................................................................................10168
Fuel Filler Cap.....................................................................................................................10171
Fuel Filter.........................................................................................................................10171
Fuel Injectors......................................................................................................................10173
Fuel Pressure Regulator.............................................................................................................10174
Fuel Pump Assembly..................................................................................................................10176
Fuel Pump Relay.....................................................................................................................10178
Fuel Rail Assembly..................................................................................................................10178
Fuel Tank...........................................................................................................................10180
Throttle body (TB)..................................................................................................................10181
ELECTRONIC IGNITION SYSTEM Ignition Control Module (ICM)............................................................................10183
Ignition Coil.......................................................................................................................10183
Spark Plugs.........................................................................................................................10184
Spark Plug Cables...................................................................................................................10185
EMISSIONS Catalytic Converter.......................................................................................................10186
Air Conditioning Relay..............................................................................................................10186
Ignition Timing Adjustment..........................................................................................................10186
EVAP Canister Hoses.................................................................................................................10186
EVAP Canister.......................................................................................................................10186
EVAP Canister Vent Solenoid.........................................................................................................10187
EVAP Canister Purge Valve Solenoid..................................................................................................10187
Linear Exhaust Gas Recirculation (EGR) Valve........................................................................................10188
Wiring and Connectors...............................................................................................................10190
PCM Connectors And Terminals........................................................................................................10190
Connectors And Terminals............................................................................................................10190
Wire Harness Repair: Twisted Shielded Cable.........................................................................................10190
Twisted Leads.......................................................................................................................10191
Weather-Pack Connector..............................................................................................................10192
Com-Pack III........................................................................................................................10194
Metri-Pack..........................................................................................................................10194
GENERAL DESCRIPTION - PCM AND SENSORS...............................................................................................10195
58X Reference PCM Input.........................................................................................................10195
A/C Request Signal..............................................................................................................10195
Crankshaft Position (CKP) Sensor................................................................................................10195
Camshaft Position (CMP) Sensor And Signal.......................................................................................10195
Engine Coolant Temperature (ECT) Sensor.........................................................................................10195
Electrically Erasable Programmable Read Only Memory (EEPROM)....................................................................10196
Fuel Control Heated Oxygen Sensor (Pre Catalyst)................................................................................10196
Catalyst Monitor Heated Oxygen Sensor (Post Catalyst)...........................................................................10196
Intake Air Temperature (IAT) Sensor.............................................................................................10197
Linear Exhaust Gas Recirculation (EGR) Control..................................................................................10197
Manifold Absolute Pressure (MAP) Sensor.........................................................................................10197
Powertrain Control Module (PCM).................................................................................................10198
PCM Function....................................................................................................................10198
PCM Components..................................................................................................................10198
PCM Voltage Description.........................................................................................................10198
PCM Inputs/Outputs..............................................................................................................10198
PCM Service Precautions.........................................................................................................10199
Reprogramming the PCM...........................................................................................................10199
Tooth Error Correction (TEC) Service Bay Guidelines.............................................................................10199
Throttle Position (TP) Sensor...................................................................................................10200
Transmission Range Switch.......................................................................................................10200
Vehicle Speed Sensor (VSS)......................................................................................................10200
Use of Circuit Testing Tools....................................................................................................10201
Aftermarket Electrical And Vacuum Equipment.....................................................................................10201
Electrostatic Discharge Damage..................................................................................................10201
Upshift Lamp....................................................................................................................10201
GENERAL DESCRIPTION - AIR INDUCTION.................................................................................................10201
Air Induction System............................................................................................................10201
GENERAL DESCRIPTION - FUEL METERING.................................................................................................10202
Acceleration Mode...............................................................................................................10202
Accelerator Controls............................................................................................................10202
Battery Voltage Correction Mode.................................................................................................10202
CMP Signal......................................................................................................................10202
Clear Flood Mode................................................................................................................10202
Deceleration Fuel Cutoff (DFCO) Mode............................................................................................10202
Engine Speed/Vehicle Speed/ Fuel Disable Mode...................................................................................10202
Fuel Cutoff Mode................................................................................................................10202
Fuel Injector...................................................................................................................10202
Fuel Metering System Components.................................................................................................10203
Fuel Metering System Purpose....................................................................................................10203
Fuel Pressure Regulator.........................................................................................................10203
Fuel Pump Electrical Circuit....................................................................................................10203
Fuel Rail.......................................................................................................................10203
Idle Air Control (IAC) Valve....................................................................................................10204
Run Mode........................................................................................................................10204
Starting Mode...................................................................................................................10204
Throttle Body Unit..............................................................................................................10204
GENERAL DESCRIPTION - ELECTRONIC IGNITION SYSTEM...................................................................................10205
Camshaft Position (CMP) Sensor..................................................................................................10205
Crankshaft Position (CKP) Sensor................................................................................................10205
Electronic Ignition.............................................................................................................10205
Ignition Coils..................................................................................................................10205
Ignition Control................................................................................................................10205
Ignition Control Module (ICM)...................................................................................................10206
Ignition Control PCM Output.....................................................................................................10206
Powertrain Control Module (PCM).................................................................................................10206
Spark Plug......................................................................................................................10207
A/C CLUTCH DIAGNOSIS................................................................................................................10208
A/C Clutch Circuit Operation....................................................................................................10208
A/C Clutch Circuit Purpose......................................................................................................10208
A/C Request Signal..............................................................................................................10208
GENERAL DESCRIPTION - EVAPORATIVE EMISSION (EVAP) SYSTEM............................................................................10209
EVAP Emission Control System Purpose............................................................................................10209
EVAP Emission Control System Operation..........................................................................................10209
Enhanced Evaporative Emission Control System....................................................................................10209
Enhanced Evaporative Emission Control System....................................................................................10209
System Fault Detection..........................................................................................................10210
GENERAL DESCRIPTION - EXHAUST GAS RECIRCULATION (EGR) SYSTEM........................................................................10210
EGR Purpose.....................................................................................................................10210
Linear EGR Valve................................................................................................................10210
Linear EGR Control..............................................................................................................10210
Linear EGR Valve Operation And Results Of Incorrect Operation...................................................................10211
EGR Pintle Position Sensor......................................................................................................10211
GENERAL DESCRIPTION - POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM...................................................................10211
Crankcase Ventilation System Purpose............................................................................................10211
SPECIAL TOOLS.......................................................................................................................10212
6F ENGINE EXHAUST.....................................................................................................................10214
Service Precaution..................................................................................................................10214
General Description.................................................................................................................10215
Front Exhaust Pipe..................................................................................................................10216
Front Exhaust Pipe and Associated Parts.........................................................................................10216
Removal.........................................................................................................................10216
Installation....................................................................................................................10216
Exhaust Silencer....................................................................................................................10217
Exhaust Silencer and Associated Parts...........................................................................................10217
Removal.........................................................................................................................10217
Installation....................................................................................................................10217
Rear Exhaust pipe...................................................................................................................10218
Rear Exhaust pipe and Associated Parts..........................................................................................10218
Removal.........................................................................................................................10218
Installation....................................................................................................................10218
Main Data and Specifications........................................................................................................10219
6G ENGINE LUBRICATION.................................................................................................................10220
Service Precaution..................................................................................................................10220
General Description.................................................................................................................10221
Oil Pump............................................................................................................................10222
Oil Pump and Associated Parts...................................................................................................10222
Disassembly.....................................................................................................................10223
Inspection and Repair...........................................................................................................10223
Reassembly......................................................................................................................10223
6H ENGINE SPEED CONTROL SYSTEM........................................................................................................10224
Service Precaution..................................................................................................................10224
Accelerator Pedal Control Cable.....................................................................................................10225
Removal.........................................................................................................................10225
Inspection......................................................................................................................10225
Installation....................................................................................................................10225
Accelerator Pedal...................................................................................................................10226
Accelerator Pedal and Associated Parts..........................................................................................10226
Removal.........................................................................................................................10226
Installation....................................................................................................................10226
6J INDUCTION..........................................................................................................................10227
Service Precaution..................................................................................................................10227
Air Cleaner Filter..................................................................................................................10228
Removal.........................................................................................................................10228
Inspection......................................................................................................................10228
Installation....................................................................................................................10228
6VD1 3.2L ENGINE...........................................................................................................................10229
6A ENGINE MECHANICAL..................................................................................................................10229
Service Precaution..................................................................................................................10230
General Description.................................................................................................................10231
Engine Diagnosis....................................................................................................................10232
Cylinder Head Cover LH..............................................................................................................10247
Removal.........................................................................................................................10247
Installation....................................................................................................................10248
Cylinder Head Cover RH..............................................................................................................10249
Removal.........................................................................................................................10249
Installation....................................................................................................................10249
Common Chamber......................................................................................................................10250
Removal.........................................................................................................................10250
Installation....................................................................................................................10250
Exhaust Manifold LH.................................................................................................................10252
Removal.........................................................................................................................10252
Installation....................................................................................................................10252
Exhaust Manifold RH.................................................................................................................10253
Removal.........................................................................................................................10253
Installation....................................................................................................................10253
Crankshaft Pulley...................................................................................................................10254
Removal.........................................................................................................................10254
Installation....................................................................................................................10254
Timing Belt.........................................................................................................................10255
Removal.........................................................................................................................10255
Installation....................................................................................................................10256
Camshaft............................................................................................................................10260
Removal.........................................................................................................................10260
Installation....................................................................................................................10261
Cylinder Head.......................................................................................................................10263
Removal.........................................................................................................................10263
Installation....................................................................................................................10263
Valve Stem Oil Controller , Valve Spring and Valve Guide............................................................................10265
Removal.........................................................................................................................10265
Installation....................................................................................................................10265
Piston, Piston Ring and Connecting Rod..............................................................................................10266
Removal.........................................................................................................................10266
Installation....................................................................................................................10267
Crankshaft and Main Bearings........................................................................................................10268
Removal.........................................................................................................................10268
Installation....................................................................................................................10269
Rear Oil Seal.......................................................................................................................10273
Removal.........................................................................................................................10273
Installation....................................................................................................................10273
Engine Assembly.....................................................................................................................10274
Removal.........................................................................................................................10274
Installation....................................................................................................................10275
Cylinder Head.......................................................................................................................10277
Cylinder Head and Associated Parts..............................................................................................10277
Disassembly.....................................................................................................................10277
Clean...........................................................................................................................10278
Inspection and Repair...........................................................................................................10278
Reassembly......................................................................................................................10279
Valve Spring, Oil Controller, Valve, Valve Guide....................................................................................10281
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts...........................................................10281
Disassembly.....................................................................................................................10281
Inspection and Repair...........................................................................................................10282
Reassembly......................................................................................................................10285
Camshaft............................................................................................................................10288
Camshaft and Associated Parts...................................................................................................10288
Disassembly.....................................................................................................................10288
Inspection and Repair...........................................................................................................10289
Reassembly......................................................................................................................10291
Crankshaft..........................................................................................................................10294
Crankshaft and Associated Parts.................................................................................................10294
Disassembly.....................................................................................................................10294
Inspection and Repair...........................................................................................................10295
Inspection and Repair...........................................................................................................10297
Reassembly......................................................................................................................10298
Piston and Connecting Rod...........................................................................................................10302
Piston, Connecting Rod and Associate Parts......................................................................................10302
Disassembly.....................................................................................................................10302
Inspection and Repair...........................................................................................................10303
Reassembly......................................................................................................................10307
Cylinder Block......................................................................................................................10309
Cylinder Block and Associated Parts.............................................................................................10309
Disassembly.....................................................................................................................10309
Inspection and Repair...........................................................................................................10310
Reassembly......................................................................................................................10311
Main Data and Specification.........................................................................................................10314
Special Tool........................................................................................................................10320
6B ENGINE COOLING.....................................................................................................................10322
Service Precaution..................................................................................................................10322
General Description.................................................................................................................10323
Diagnosis...........................................................................................................................10325
Draining and Refilling Cooling System...............................................................................................10326
Water Pump..........................................................................................................................10327
Water Pump and Associated Parts.................................................................................................10327
Removal.........................................................................................................................10327
Inspection......................................................................................................................10327
Installation....................................................................................................................10327
Thermostat..........................................................................................................................10328
Thermostat and Associated Parts.................................................................................................10328
Removal.........................................................................................................................10328
Inspection......................................................................................................................10328
Installation....................................................................................................................10328
Radiator............................................................................................................................10329
Radiator and Associated Parts...................................................................................................10329
Removal.........................................................................................................................10329
Inspection......................................................................................................................10330
Installation....................................................................................................................10331
Drive Belt and Cooling Fan..........................................................................................................10332
Drive Belt and Associated Parts.................................................................................................10332
Inspection......................................................................................................................10332
Installation....................................................................................................................10332
Main Data and Specifications........................................................................................................10333
Special Tool........................................................................................................................10334
6C ENGINE FUEL........................................................................................................................10335
Service Precaution..................................................................................................................10335
General Description.................................................................................................................10336
Fuel Metering.......................................................................................................................10337
Fuel Filter.........................................................................................................................10338
Removal.............................................................................................................................10338
Inspection..........................................................................................................................10338
Installation........................................................................................................................10338
Inspection..........................................................................................................................10338
In-Tank Fuel Filter.................................................................................................................10338
Fuel Pump Flow Test.................................................................................................................10339
Fuel Pump...........................................................................................................................10340
Fuel Pump and Associated Parts..................................................................................................10340
Removal.........................................................................................................................10340
Installation....................................................................................................................10340
Fuel Tube / Quick - Connector Fittings..............................................................................................10341
Precautions.....................................................................................................................10341
Cautions During Work............................................................................................................10341
Removal.........................................................................................................................10341
Reuse of Quick-Connector........................................................................................................10342
Assembling Advice...............................................................................................................10343
Fuel Pump Relay.....................................................................................................................10343
General Description.............................................................................................................10343
Fuel Tank...........................................................................................................................10344
Fuel Tank and Associated Parts..................................................................................................10344
Removal.........................................................................................................................10344
Installation....................................................................................................................10345
Fuel Gauge Unit.....................................................................................................................10345
Removal and Installation........................................................................................................10345
Fuel Filler Cap.....................................................................................................................10345
General Description.............................................................................................................10345
Inspection......................................................................................................................10345
Main Data and Specifications........................................................................................................10346
6D1 ENGINE ELECTRICAL..................................................................................................................10347
Service Precaution..................................................................................................................10347
Battery.............................................................................................................................10348
General Description.............................................................................................................10348
Diagnosis.......................................................................................................................10348
Battery Charging................................................................................................................10349
Jump Starting...................................................................................................................10349
Battery Removal.................................................................................................................10350
Battery Installation............................................................................................................10350
Main Data and Specifications........................................................................................................10351
6D2 IGNITION SYSTEM....................................................................................................................10352
Service Precaution..................................................................................................................10352
General Description.................................................................................................................10353
Diagnosis...........................................................................................................................10353
Ignition Coil.......................................................................................................................10354
Removal.........................................................................................................................10354
Inspection and Repair...........................................................................................................10354
Installation....................................................................................................................10354
Spark Plug..........................................................................................................................10356
Removal.........................................................................................................................10356
Inspection and Repair...........................................................................................................10356
Installation....................................................................................................................10356
Crankshaft Position Sensor..........................................................................................................10357
Removal.........................................................................................................................10357
Installation....................................................................................................................10357
Main Data and Specifications........................................................................................................10358
6D3 STARTING AND CHARGING SYSTEM.......................................................................................................10359
Service Precaution..................................................................................................................10359
Starting System.....................................................................................................................10360
General Description.................................................................................................................10360
Diagnosis...........................................................................................................................10362
Starter.............................................................................................................................10363
Removal.........................................................................................................................10363
Installation....................................................................................................................10363
Disassembled View...............................................................................................................10364
Disassembly.....................................................................................................................10365
Inspection and Repair...........................................................................................................10367
Reassembly......................................................................................................................10371
Main Data and Specifications....................................................................................................10373
Charging System.....................................................................................................................10376
General Description.................................................................................................................10376
General On-Vehicle Inspection.......................................................................................................10376
Generator...........................................................................................................................10377
Removal.........................................................................................................................10377
Inspection......................................................................................................................10377
Installation....................................................................................................................10378
Disassembled View...............................................................................................................10378
Disassembly.....................................................................................................................10379
Inspection and Repair...........................................................................................................10380
Reassembly......................................................................................................................10382
Bench Test......................................................................................................................10383
Main Data and Specifications........................................................................................................10384
6E2 RODEO 3.2L ENGINE..................................................................................................................10385
Specifications......................................................................................................................10390
Tightening Specifications.......................................................................................................10390
Diagrams and Schematics.............................................................................................................10391
PCM Wiring Diagram (1 of 7).....................................................................................................10391
PCM Wiring Diagram (2 of 7).....................................................................................................10392
PCM Wiring Diagram (3 of 7).....................................................................................................10393
PCM Wiring Diagram (4 of 7).....................................................................................................10394
PCM Wiring Diagram (5 of 7).....................................................................................................10395
PCM Wiring Diagram (6 of 7).....................................................................................................10396
PCM Wiring Diagram (7 of 7).....................................................................................................10397
PCM Pinouts.........................................................................................................................10398
PCM Pinout Table, 80-Way Blue Connector-Row "F1 ~ 20"...........................................................................10398
PCM Pinout Table, 80-Way Blue Connector-Row "F20 ~ 40"..........................................................................10400
PCM Pinout Table, 80-Way Blue Connector-Row "F41 ~ 60"..........................................................................10401
PCM Pinout Table, 80-Way Blue Connector-Row "F61 ~ 80"..........................................................................10402
PCM Pinout Table, 80-Way Red Connector-Row "S1 ~ 20"............................................................................10404
PCM Pinout Table, 80-Way Red Connector-Row "S21 ~ 40"...........................................................................10406
PCM Pinout Table, 80-Way Red Connector-Row "S41 ~ 60"...........................................................................10408
PCM Pinout Table, 80-Way Red Connector-Row "S61 ~ 80"...........................................................................10410
Component Locators..................................................................................................................10412
Engine Component Locator........................................................................................................10412
Engine Component Locator Table..................................................................................................10413
Undercarriage Component Locator.................................................................................................10414
Undercarriage Component Locator Table...........................................................................................10414
Fuse and Relay Panel (Underhood Electrical Center)..............................................................................10415
Sensors and Miscellaneous Component Locators....................................................................................10416
Diagnosis...........................................................................................................................10419
Strategy-Based Diagnostics......................................................................................................10419
DTC Stored......................................................................................................................10419
No DTC..........................................................................................................................10419
No Matching Symptom.............................................................................................................10419
Intermittents...................................................................................................................10419
No Trouble Found................................................................................................................10419
Verifying Vehicle Repair........................................................................................................10419
General Service Information.........................................................................................................10419
OBD II Serviceablity Issues.....................................................................................................10419
Emissions Control Information Label.............................................................................................10420
Visual / Physical Engine Compartment Inspection.................................................................................10420
Basic Knowledge of Tools Required...............................................................................................10421
Serial Data Communications..........................................................................................................10421
Class II Serial Data Communications.............................................................................................10421
On-Board Diagnostic (OBD II)........................................................................................................10421
On-Board Diagnostic Tests.......................................................................................................10421
Comprehensive Component Monitor Diagnostic Operation............................................................................10421
System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...............................10422
Common OBD II Terms.............................................................................................................10422
The Diagnostic Executive........................................................................................................10422
DTC Types.......................................................................................................................10423
Decimal/Binary/Hexadecimal Conversions..........................................................................................10425
Verifying Vehicle Repair........................................................................................................10425
Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool.....................................................................10425
Tech 2..........................................................................................................................10426
Tech 2 Features.................................................................................................................10427
Getting Started.................................................................................................................10427
Operating Procedure (For Example)...............................................................................................10428
DTC Modes.......................................................................................................................10429
DTC Information Mode............................................................................................................10429
Miscellaneous Test..............................................................................................................10430
Lamps Test......................................................................................................................10430
Relays Test.....................................................................................................................10432
EVAP Test.......................................................................................................................10433
Fuel System Test................................................................................................................10434
Instruments Test................................................................................................................10436
EGR Control Test................................................................................................................10438
Variable Intake Manifold Solenoid Test..........................................................................................10438
Injector Balance Test...........................................................................................................10440
Plotting Snapshot Graph.............................................................................................................10440
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)..................................................10441
Flow Chart for Snapshot Replay (Plotting Graph).................................................................................10442
Primary System-Based Diagnostic.....................................................................................................10443
Fuel Control Heated Oxygen Sensor...............................................................................................10443
HO2S Heater.....................................................................................................................10443
Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation.................................................................10443
Evaporative Emission (EVAP) Purge System Vacuum Switch..........................................................................10444
Misfire Monitor Diagnostic Operation................................................................................................10444
Misfire Counters................................................................................................................10445
Fuel Trim System Monitor Diagnostic Operation.......................................................................................10445
Fuel Trim Cell Diagnostic Weights...............................................................................................10445
On-Board Diagnostic (OBD II) System Check...........................................................................................10446
A/C Clutch Control Circuit Diagnosis................................................................................................10449
Electronic Ignition System Diagnosis................................................................................................10454
EVAP Canister Purge Solenoid and EVAP Vacuum Switch.................................................................................10454
Visual Check of The Evaporative Emission Canister...................................................................................10454
Fuel Metering System Check..........................................................................................................10454
Fuel System Pressure Test...........................................................................................................10454
Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure..........................................................10454
Powertrain Control Module (PCM) Diagnosis...........................................................................................10459
Multiple PCM Information Sensor DTCs Set............................................................................................10459
Exhaust Gas Recirculation (EGR) Diagnosis...........................................................................................10463
Engine Tech 2 Data Definitions and Ranges...........................................................................................10463
Typical Scan Data Values............................................................................................................10465
No Malfunction Indicator Lamp (MIL).................................................................................................10471
Malfunction Indicator Lamp (MIL) "ON" Steady........................................................................................10474
No Reduced Power Lamp (RPL).........................................................................................................10476
Reduced Power Lamp (RPL) "ON" Steady................................................................................................10480
Engine Cranks But Will Not Run......................................................................................................10483
Fuel System Electrical Test.........................................................................................................10490
Electric Throttle Control (ETC) System Check........................................................................................10494
Fuel System Diagnosis...............................................................................................................10498
Exhaust Gas Recirculation (EGR) System Check........................................................................................10503
Manifold Absolute Pressure (MAP) Output Check.......................................................................................10505
Evaporative (EVAP) Emissions Canister Purge Valve Check.............................................................................10507
Upshift Lamp System Check (Manual Transmission Only)................................................................................10510
PCM Diagnostic Trouble Codes........................................................................................................10514
Diagnostic Trouble Code (DTC) P0101 MAF System Performance..........................................................................10518
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency................................................................10521
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency...............................................................10524
Diagnostic Trouble Code (DTC) P0106 MAP System Performance..........................................................................10527
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage..................................................................10530
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage.................................................................10533
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage..................................................................10536
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage.................................................................10539
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage..................................................................10542
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage.................................................................10545
Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control..................................................10548
Diagnostic Trouble Code(DTC) P0128 Thermostat Insufficient temperrature for Stable Opreation........................................10551
Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1........................................................10554
Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1.......................................................10557
Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1..............................................................10560
Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1..............................................10564
Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1.............................................................10567
Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2........................................................10570
Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2.......................................................10573
Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2...............................................10576
Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2.............................................................10579
Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1........................................................10582
Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1.......................................................10585
Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1..............................................................10588
Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1..............................................10592
Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Bank 2 Sensor 1.............................................................10595
Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2........................................................10598
Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2.......................................................10601
Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2..............................................10604
Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2.............................................................10607
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1....................................................................10610
Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1....................................................................10614
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2....................................................................10618
Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2....................................................................10622
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit......................................................................10626
Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit......................................................................10629
Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit......................................................................10632
Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit......................................................................10635
Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit......................................................................10638
Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit......................................................................10641
Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected.........................................................................10644
Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected.......................................................................10648
Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected.......................................................................10650
Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected.......................................................................10652
Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected.......................................................................10654
Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected.......................................................................10656
Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected.......................................................................10658
Diagnostic Trouble Code (DTC) P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault....................................10660
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit....................................................................10663
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency................................................................10666
Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performance..................................................................10669
Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low..........................................................................10673
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit......................................................................10677
Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit......................................................................10680
Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit......................................................................10683
Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit......................................................................10686
Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit......................................................................10689
Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit......................................................................10692
Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient...........................................................................10695
Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error..........................................................................10698
Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck..................................................................................10700
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage.................................................................................10702
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage................................................................................10705
Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1................................................................10708
Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2................................................................10711
Diagnostic Trouble Code (DTC) P0440 EVAP System.....................................................................................10714
Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected.................................................................10717
Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Blocked......................................................................10720
Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor Low Voltage...........................................................10723
Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor (Vapor pressure Sensor) High Voltage..................................10726
Diagnostic Trouble Code (DTC) P0456 EVAP Very Small Leak............................................................................10729
Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit-Low Voltage...........................................................10732
Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit-High Voltage..........................................................10735
Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input...........................................................................10737
Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM.................................................................10740
Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM................................................................10743
Diagnostic Trouble Code (DTC) P0562 System Voltage Low..............................................................................10746
Diagnostic Trouble Code (DTC) P0563 System Voltage High.............................................................................10748
Diagnostic Trouble Code (DTC) P0601 PCM Memory......................................................................................10750
Diagnostic Trouble Code (DTC) P0602 PCM Programming Error...........................................................................10752
Diagnostic Trouble Code (DTC) P0604 PCM RAM Error...................................................................................10754
Diagnostic Trouble Code (DTC) P0606 PCM Internal Performance........................................................................10756
Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage....................................................10758
Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage............................................................10760
Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage....................................................10762
Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage.....................................................10765
Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage.....................................................10767
Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage....................................................10769
Diagnostic Trouble Code(DTC) P1120-TPS 1 Throttle Position Sensor (TPS1) Circuit Fault..............................................10772
Diagnostic Trouble Code (DTC) P1125 ETC (Electric throttle control) Limit Performance Mode..........................................10775
Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1.....................................................10778
Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1......................................................10782
Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1.....................................................10786
Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1..............................................10790
Diagnostic Trouble Code (DTC) P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1).............................................10794
Diagnostic Trouble Code (DTC) P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2).............................................10796
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration............................................................10798
Diagnostic Trouble Code (DTC) P1220 Throttle Position Senser2 (TPS2) Circuit Fault..................................................10801
Diagnosis Truble Code(DTC) P1221 TPS1-TPS2 correlation(Circuit Performance).........................................................10804
Diagnostic Trouble Code (DTC) P1271 APS 1-2 Correlation Error.......................................................................10807
Diagnostic Trouble Code (DTC) P1272 APS 2-3 Correlation Error.......................................................................10810
Diagnostic Trouble Code (DTC) P1273 APS 1-3 Correlation Error.......................................................................10813
Diagnostic Trouble Code (DTC) P1275 APS 1 Circuit Fault.............................................................................10816
Diagnostic Trouble Code (DTC) P1280 APS 2 Circuit Fault.............................................................................10818
Diagnostic Trouble Code (DTC) P1285 APS 3 Circuit Fault.............................................................................10820
Diagnostic Trouble Code (DTC) P1290 ETC Forced Idle Mode............................................................................10822
Diagnostic Trouble Code (DTC) P1295 Power Management Mode...........................................................................10825
Diagnostic Trouble Code (DTC) P1299 ETC Forced Engine Shutdown Mode.................................................................10829
Diagnostic Trouble Code (DTC) P1310 ION Sensing Module Diagnosis....................................................................10833
Diagnostic Trouble Code (DTC) P1311 ION Sensing Module SEC line 1 Circuit Fault.....................................................10836
Diagnostic Trouble Code (DTC) P1312 ION Sensing Module SEC line 2 Circuit Fault.....................................................10839
Diagnostic Trouble Code (DTC) P1326 ION Sensing Module Combustion Quality Input Circuit Fault.......................................10842
Diagnostic Trouble Code (DTC) P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)............................10845
Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed................................................................................10848
Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge...............................................................10851
Diagnostic Trouble Code (DTC) P1514 TPS - MAF Correlation Error.....................................................................10854
Diagnostic Trouble Code (DTC) P1515 Command - Actual TPS Correlation Error..........................................................10858
Diagnostic Trouble Code (DTC) P1516 Command - Actual TPS Correlation Error..........................................................10861
Diagnostic Trouble Code (DTC) P1523 Actuator Control Return Performance.............................................................10864
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset............................................................................10867
Diagnostic Trouble Code (DTC) P1635 Reference Voltage # 1 Circuit Fault.............................................................10868
Diagnostic Trouble Code (DTC) P1639 Reference Voltage # 2 Circuit Fault.............................................................10870
Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM).............................................................10872
Diagnostic Trouble Code (DTC) P1650 Quad Driver Module "A" Fault....................................................................10875
Symptom Diagnosis...................................................................................................................10878
Default Matrix Table................................................................................................................10907
On-Vehicle Service Camshaft Position (CMP) Sensor...................................................................................10910
Crankshaft Position (CKP) Sensor....................................................................................................10911
Engine Coolant Temperature (ECT) Sensor.............................................................................................10911
Heated Oxygen Sensor (HO2S).........................................................................................................10912
Intake Air Temperature (IAT) Sensor.................................................................................................10915
ION Sensing Module..................................................................................................................10915
Mass Air Flow (MAF) Sensor..........................................................................................................10916
Manifold Absolute Pressure (MAP) Sensor.............................................................................................10917
Malfunction Indicator Lamp (MIL)....................................................................................................10918
Reduced Power Lamp..................................................................................................................10918
Powertrain Control Module (PCM).....................................................................................................10918
EEPROM..............................................................................................................................10919
Throttle Position (TP) Sensor.......................................................................................................10920
Vehicle Speed Sensor (VSS)..........................................................................................................10920
Air Cleaner/Air Filter..............................................................................................................10922
Common Chamber......................................................................................................................10922
Accelerator Pedal Replacement.......................................................................................................10923
Fuel Filler Cap.....................................................................................................................10924
Fuel Filter.........................................................................................................................10924
Fuel Gauge Unit.....................................................................................................................10925
Fuel Injectors......................................................................................................................10926
Fuel Metering System................................................................................................................10927
Fuel Pump Assembly..................................................................................................................10927
Fuel Pump Relay.....................................................................................................................10927
Fuel Rail Assembly..................................................................................................................10928
Fuel Tank...........................................................................................................................10929
Throttle Body (TB)..................................................................................................................10929
Electronic Ignition System..........................................................................................................10931
Catalytic Converter.................................................................................................................10932
Air Conditioning Thermo Relay.......................................................................................................10932
EVAP Canister Hoses.................................................................................................................10933
EVAP Canister.......................................................................................................................10933
EVAP Canister Vent Solenoid.........................................................................................................10935
Fuel Tank Pressure Sensor...........................................................................................................10936
EVAP Canister Purge Solenoid........................................................................................................10936
Fuel Tank Vent Valve................................................................................................................10937
Linear Exhaust Gas Recirculation (EGR) Valve........................................................................................10938
Positive Crankcase Ventilation (PCV) Valve..........................................................................................10939
Wiring and Connectors...............................................................................................................10939
PCM Connectors and Terminals........................................................................................................10940
Wire Harness Repair: Twisted Shielded Cable.........................................................................................10940
Twisted Leads.......................................................................................................................10941
Weather-Pack Connector..............................................................................................................10942
Com-Pack III........................................................................................................................10943
Metri-Pack..........................................................................................................................10943
General Description (PCM and Sensors)...............................................................................................10945
58X Reference PCM Input.........................................................................................................10945
A/C Request Signal..............................................................................................................10945
Crankshaft Position (CKP) Sensor................................................................................................10945
Camshaft Position (CMP) Sensor and Signal.......................................................................................10945
Engine Coolant Temperature (ECT) Sensor.........................................................................................10945
Electrically Erasable Programmable Read Only Memory (EEPROM)....................................................................10946
Fuel Control Heated Oxygen Sensors..............................................................................................10946
Catalyst Monitor Heated Oxygen Sensors..........................................................................................10946
Intake Air Temperature (IAT) Sensor.............................................................................................10947
Linear Exhaust Gas Recirculation (EGR) Control..................................................................................10947
Mass Air Flow (MAF) Sensor......................................................................................................10947
Manifold Absolute Pressure (MAP) Sensor.........................................................................................10947
Powertrain Control Module (PCM).................................................................................................10948
PCM Function....................................................................................................................10948
PCM Components..................................................................................................................10948
PCM Voltage Description.........................................................................................................10948
PCM Input/Outputs...............................................................................................................10949
PCM Service Precautions.........................................................................................................10949
Reprogramming The PCM...........................................................................................................10949
Throttle Position (TP) Sensor...................................................................................................10949
Transmission Fluid Temperature (TFT) Sensor.....................................................................................10949
Transmission Range Switch.......................................................................................................10949
Vehicle Speed Sensor (VSS)......................................................................................................10950
Use of Circuit Testing Tools....................................................................................................10950
Aftermarket Electrical and Vacuum Equipment.....................................................................................10950
Electrostatic Discharge Damage..................................................................................................10950
Upshift Lamp....................................................................................................................10950
General Description (Air Induction).................................................................................................10950
Air Induction System............................................................................................................10950
General Description (Fuel Metering).................................................................................................10951
Acceleration Mode...............................................................................................................10951
Battery Voltage Correction Mode.................................................................................................10951
CMP Signal......................................................................................................................10951
Clear Flood Mode................................................................................................................10951
Deceleration Mode...............................................................................................................10951
Engine Speed/Vehicle Speed/Fuel Disable Mode....................................................................................10951
Fuel Cutoff Mode................................................................................................................10951
Fuel Injector...................................................................................................................10951
Fuel Metering System Components.................................................................................................10951
Basic System Operation..........................................................................................................10952
Fuel Metering System Purpose....................................................................................................10952
Fuel Pressure Regulator.........................................................................................................10952
Fuel Pump Electrical Circuit....................................................................................................10952
Fuel Rail.......................................................................................................................10952
Run Mode........................................................................................................................10953
Starting Mode...................................................................................................................10953
Throttle Body Unit..............................................................................................................10953
General Description (Electronic Ignition System)....................................................................................10953
Camshaft Position (CMP) Sensor..................................................................................................10953
Crankshaft Position (CKP) Sensor................................................................................................10953
Electronic Ignition.............................................................................................................10954
Ignition Coils..................................................................................................................10954
Ignition Control................................................................................................................10954
Ignition Control PCM Output.....................................................................................................10955
Powertrain Control Module (PCM).................................................................................................10955
Spark Plug......................................................................................................................10956
A/C Clutch Diagnosis................................................................................................................10957
A/C Clutch Circuit Operation....................................................................................................10957
A/C Clutch Circuit Purpose......................................................................................................10957
A/C Request Signal..............................................................................................................10957
General Description (Evaporative (EVAP) Emission System)............................................................................10958
EVAP Emission Control System Purpose............................................................................................10958
EVAP Emission Control System Operation..........................................................................................10958
Enhanced Evaporative Emission Control System....................................................................................10958
General Description (Exhaust Gas Recirculation (EGR) System)........................................................................10961
EGR Purpose.....................................................................................................................10961
Linear EGR Valve................................................................................................................10962
Linear EGR Control..............................................................................................................10962
Linear EGR Valve Operation and Results of Incorrect Operation...................................................................10962
EGR Pintle Position Sensor......................................................................................................10962
General Description (Positive Crankcase Ventilation (PCV) System)...................................................................10962
Crankcase Ventilation System Purpose............................................................................................10962
Crankcase Ventilation System Operation..........................................................................................10962
Special Tools.......................................................................................................................10964
6F ENGINE EXHAUST.....................................................................................................................10966
Service Precaution..................................................................................................................10966
General Description.................................................................................................................10967
Three Way Catalytic Converter RH and Forked Exhaust Pipe............................................................................10968
Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts...................................................10968
Removal.........................................................................................................................10968
Installation....................................................................................................................10968
Three Way Catalytic Converter LH and Forked Exhaust Pipe............................................................................10969
Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated Parts...................................................10969
Removal.........................................................................................................................10969
Installation....................................................................................................................10969
Forked Exhaust Pipe.................................................................................................................10970
Forked Exhaust Pipe and Associated Parts........................................................................................10970
Removal.........................................................................................................................10970
Installation....................................................................................................................10970
Exhaust Silencer....................................................................................................................10971
Exhaust Silencer and Associated Parts...........................................................................................10971
Removal.........................................................................................................................10971
Installation....................................................................................................................10971
Rear Exhaust pipe...................................................................................................................10972
Rear Exhaust pipe and Associated Parts..........................................................................................10972
Removal.........................................................................................................................10972
Installation....................................................................................................................10972
Main Data and Specifications........................................................................................................10973
6G ENGINE LUBRICATION.................................................................................................................10974
Service Precaution..................................................................................................................10974
General Description.................................................................................................................10975
Oil Pump............................................................................................................................10976
Oil Pump and Associated Parts...................................................................................................10976
Disassembly.....................................................................................................................10977
Inspection and Repair...........................................................................................................10977
Reassembly......................................................................................................................10978
Oil Pan and Crankcase...............................................................................................................10980
Removal.........................................................................................................................10980
Installation....................................................................................................................10980
Oil Pump............................................................................................................................10982
Removal.........................................................................................................................10982
Installation....................................................................................................................10982
Oil Pump Oil Seal...................................................................................................................10984
Removal.........................................................................................................................10984
Installation....................................................................................................................10984
Oil Filter..........................................................................................................................10985
Removal.........................................................................................................................10985
Installation....................................................................................................................10985
Main Data and Specification.........................................................................................................10986
6H ENGINE SPEED CONTROL SYSTEM........................................................................................................10987
Service Precaution..................................................................................................................10987
Accelerator Pedal...................................................................................................................10988
Accelerator Pedal and Associated Parts..........................................................................................10988
Removal.........................................................................................................................10988
Installation....................................................................................................................10988
6J INDUCTION..........................................................................................................................10989
Service Precaution..................................................................................................................10989
Air Cleaner Element.................................................................................................................10990
Removal.........................................................................................................................10990
Inspection......................................................................................................................10990
Installation....................................................................................................................10990
Sec.7 TRANSMISSION............................................................................................................................11234
7A AUTOMATIC TRANSMISSION (4L30-E).......................................................................................................10991
Service Precaution......................................................................................................................10992
Construction............................................................................................................................10993
Range Reference Chart...................................................................................................................10994
Normal Operation of 2000 4L30-E Transmission............................................................................................10995
Diagnosis...............................................................................................................................10995
Driver Information......................................................................................................................10995
General Diagnosis Procedure.............................................................................................................10998
Preliminary Inspection Chart............................................................................................................10999
Checking Transmission Fluid and Condition...............................................................................................11000
Test Driving............................................................................................................................11001
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................11002
Mechanical / Hydraulic Diagnosis Symptoms Index.........................................................................................11003
Possible Causes of Fluid Leaks Due To Sealing Malfunction...............................................................................11012
Stall Test..............................................................................................................................11012
Line Pressure Test......................................................................................................................11013
Shift Speed Chart.......................................................................................................................11014
Lockup Speed Chart......................................................................................................................11015
Changing Transmission Fluid.............................................................................................................11016
Selector Lever..........................................................................................................................11016
Inspection..........................................................................................................................11016
Removal.............................................................................................................................11016
Installation........................................................................................................................11018
Select Cable............................................................................................................................11018
Removal.............................................................................................................................11018
Installation........................................................................................................................11021
Shift Lock Cable........................................................................................................................11023
Removal.............................................................................................................................11023
Installation........................................................................................................................11023
Mode Switch.............................................................................................................................11024
Removal.............................................................................................................................11024
Installation........................................................................................................................11025
Transmission (With Transfer Case).......................................................................................................11026
Transmission and Associated Parts...................................................................................................11026
Removal.............................................................................................................................11027
Installation........................................................................................................................11032
Solenoid (Main Case Valve...............................................................................................................11036
Removal.............................................................................................................................11036
Installation........................................................................................................................11036
Solenoid (Adapter Case Valve Body)......................................................................................................11037
Removal.............................................................................................................................11037
Installation........................................................................................................................11037
Valve Body Assembly (Main Case).........................................................................................................11038
Removal.............................................................................................................................11038
Installation........................................................................................................................11038
Valve Body Assembly (Adapter Case)......................................................................................................11039
Removal.............................................................................................................................11039
Installation........................................................................................................................11039
Powertrain Control Module (PCM).........................................................................................................11039
Removal.............................................................................................................................11039
Installation........................................................................................................................11039
Speed Sensor (Extension Housing)........................................................................................................11040
Removal.............................................................................................................................11040
Installation........................................................................................................................11040
Transmission Oil Temperature Sensor (Main Case).........................................................................................11041
Removal.............................................................................................................................11041
Installation........................................................................................................................11041
Front Oil Seal (Converter Housing)......................................................................................................11042
Removal.............................................................................................................................11042
Installation........................................................................................................................11042
Rear Oil Seal (Extension Housing).......................................................................................................11042
Removal.............................................................................................................................11042
Installation........................................................................................................................11042
Transmission (4L30-E)...................................................................................................................11043
Disassembly.........................................................................................................................11043
Reassembly..........................................................................................................................11047
Converter Housing and Oil Pump Assembly.................................................................................................11057
Disassembled View...................................................................................................................11057
Disassembly.........................................................................................................................11057
Inspection and Repair...............................................................................................................11057
Reassembly..........................................................................................................................11057
Oil Pump................................................................................................................................11058
Disassembled View...................................................................................................................11058
Disassembly.........................................................................................................................11058
Inspection and Repair...............................................................................................................11058
Reassembly..........................................................................................................................11058
Main Case Valve.........................................................................................................................11059
Disassembled View...................................................................................................................11059
Disassembly.........................................................................................................................11060
Inspection and Repair...............................................................................................................11060
Reassembly..........................................................................................................................11060
Adapter Case Valve Body.................................................................................................................11061
Disassembled View...................................................................................................................11061
Disassembly.........................................................................................................................11061
Inspection and Repair...............................................................................................................11061
Reassembly..........................................................................................................................11061
Third Clutch and Sprag Unit.............................................................................................................11062
Disassembled View...................................................................................................................11062
Disassembly.........................................................................................................................11062
Inspection and......................................................................................................................11063
Reassembly..........................................................................................................................11063
Third Clutch............................................................................................................................11063
Disassembled View...................................................................................................................11063
Disassemble.........................................................................................................................11064
Inspection and Repair...............................................................................................................11064
Reassembly..........................................................................................................................11064
Sprag Unit..............................................................................................................................11065
Disassembled View...................................................................................................................11065
Disassembly.........................................................................................................................11065
Inspection and Repair...............................................................................................................11065
Reassembly..........................................................................................................................11065
Second Clutch...........................................................................................................................11066
Disassembled View...................................................................................................................11066
Disassembly.........................................................................................................................11066
Inspection and Repair...............................................................................................................11067
Reassembly..........................................................................................................................11067
3-4 Accumulator Piston..................................................................................................................11068
Disassembled View...................................................................................................................11068
Disassembly.........................................................................................................................11068
Inspection and Repair...............................................................................................................11069
Reassembly..........................................................................................................................11069
Reverse Clutch Piston and Center Support................................................................................................11070
Disassembled View...................................................................................................................11070
Disassembly.........................................................................................................................11071
Inspection and Repair...............................................................................................................11071
Reassembly..........................................................................................................................11071
Overrun Clutch and Turbine Shaft........................................................................................................11072
Disassembled View...................................................................................................................11072
Disassembly.........................................................................................................................11073
Inspection and Repair...............................................................................................................11073
Reassembly..........................................................................................................................11073
Main Data and Specification.............................................................................................................11075
Special Tools...........................................................................................................................11079
4L30-E Parts List.......................................................................................................................11082
7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)...................................................................................................11089
Service Precaution......................................................................................................................11090
General Description.....................................................................................................................11090
Electronic Control Diagram..........................................................................................................11091
Powertrain Control Module (PCM).....................................................................................................11092
Control System Diagram..............................................................................................................11093
Shift Control.......................................................................................................................11094
Band Apply Control..................................................................................................................11094
Torque Converter Clutch Control.....................................................................................................11094
Line Pressure.......................................................................................................................11094
On-Board Diagnostic System..........................................................................................................11094
Fail-Safe Mechanism.................................................................................................................11094
Torque Management Control...........................................................................................................11094
ATF Warning Control.................................................................................................................11094
Reverse Lock Out Control............................................................................................................11094
Downhill Control....................................................................................................................11094
Uphill Control......................................................................................................................11094
Shift Mode Control..................................................................................................................11095
Gear Shift Control..................................................................................................................11096
Winter Drive Mode...................................................................................................................11097
Backup Mode.........................................................................................................................11097
Functions of Input / Output Components..............................................................................................11098
Diagnosis...............................................................................................................................11099
Electronic Diagnosis................................................................................................................11099
How To Diagnose The Problem.........................................................................................................11099
Check Trans Indicator...............................................................................................................11099
Diagnostic Check....................................................................................................................11099
"Check Trans" Check.................................................................................................................11100
Tech 2 OBD II Connection............................................................................................................11101
Transmission Data...................................................................................................................11106
OBD II Diagnostic Management System.................................................................................................11107
16-Terminal Data Link Connector (DLC)...............................................................................................11108
Malfunction Indicator Lamp (MIL)....................................................................................................11109
Types Of Diagnostic Trouble Codes (DTCs)............................................................................................11109
Clear DTC...........................................................................................................................11109
DTC Check...........................................................................................................................11110
PCM Precaution......................................................................................................................11110
Information On PCM..................................................................................................................11110
Intermittent Conditions.............................................................................................................11111
Transmission and PCM Identification.................................................................................................11112
Isuzu Rodeo.........................................................................................................................11112
Diagnostic Trouble Code (DTC) Identification........................................................................................11113
DTC P0218 Transmission Fluid Over Temperature...........................................................................................11114
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position......................................................................11116
DTC P0706 Transmission Range Switch (Mode Switch) Performance...........................................................................11119
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance.......................................................................11122
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input.................................................................11125
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................11128
DTC P0719 Brake Switch Circuit Low (Stuck On)...........................................................................................11131
DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input....................................................................11134
DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent.................................................................11137
DTC P0724 Brake Switch Circuit High (Stuck Off).........................................................................................11140
DTC P0730 Gear Error Without Input Speed................................................................................................11142
DTC P0742 Torque Converter Clutch (TCC) System Stuck On.................................................................................11145
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical..............................................................11147
DTC P0751 Shift Solenoid A Performance (Stuck Off)......................................................................................11149
DTC P0752 Shift Solenoid A Performance (Stuck On).......................................................................................11151
DTC P0753 Shift Solenoid A Electrical...................................................................................................11153
DTC P0756 Shift Solenoid B Performance (Stuck Off)......................................................................................11156
DTC P0757 Shift Solenoid B Performance (Stuck On).......................................................................................11158
DTC P0758 Shift Solenoid B Electrical...................................................................................................11160
DTC P1850 Brake Band Apply Solenoid Malfunction.........................................................................................11164
DTC P1860 TCC Solenoid Electrical.......................................................................................................11168
DTC P1870 Transmission Component Slipping (TCC Stuck Off)...............................................................................11171
Connector List..........................................................................................................................11173
7B MANUAL TRANSMISSION MUA 5C............................................................................................................11174
Service Precaution......................................................................................................................11174
General Description.....................................................................................................................11175
Diagnosis...............................................................................................................................11177
Rear Oil Seal (4X2).....................................................................................................................11178
Disassembled View...................................................................................................................11178
Removal.............................................................................................................................11178
Installation........................................................................................................................11178
Transmission............................................................................................................................11179
Disassembled View...................................................................................................................11179
Removal.............................................................................................................................11180
Installation........................................................................................................................11184
Transmission Case.......................................................................................................................11189
Major Component (4X2)...............................................................................................................11189
Disassembly.........................................................................................................................11190
Reassembly..........................................................................................................................11191
Transmission Case and Transfer Case.....................................................................................................11194
Major Component (4X4)...............................................................................................................11194
Disassembly.........................................................................................................................11195
Reassembly..........................................................................................................................11198
Intermediate Plate with Gear Assembly, Detent, Shift Arm, and Interlock Pin.............................................................11204
Disassembled View...................................................................................................................11204
Disassembly.........................................................................................................................11205
Inspection and Repair...............................................................................................................11206
Reassembly..........................................................................................................................11207
Reverse Gear and 5th Gear...............................................................................................................11208
Disassembled View...................................................................................................................11208
Disassembly.........................................................................................................................11209
Inspection and Repair...............................................................................................................11211
Reassembly..........................................................................................................................11211
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft.................................................................................11217
Disassmebled View...................................................................................................................11217
Disassembly.........................................................................................................................11218
Inspection and Repair...............................................................................................................11219
Reassembly..........................................................................................................................11222
Main Data and Specifications............................................................................................................11228
Special Tools (MUA).....................................................................................................................11232
7C CLUTCH................................................................................................................................11234
Service Precaution......................................................................................................................11234
General Description.....................................................................................................................11235
Diagnosis...............................................................................................................................11240
Clutch Assembly (X22SE).................................................................................................................11241
Clutch Assembly (X22SE) and Associated Parts........................................................................................11241
Removal.............................................................................................................................11241
Inspection and Repair...............................................................................................................11242
Installation........................................................................................................................11246
Clutch Assembly (6VD1)..................................................................................................................11248
Clutch Assembly (6VD1) and Associated Parts.........................................................................................11248
Removal.............................................................................................................................11248
Inspection and Repair...............................................................................................................11250
Installation........................................................................................................................11254
Clutch Control..........................................................................................................................11256
Parts Location View.................................................................................................................11256
Removal.............................................................................................................................11257
Inspection and Repair...............................................................................................................11257
Installation........................................................................................................................11257
Master Cylinder.........................................................................................................................11260
Slave Cylinder..........................................................................................................................11261
Disassembled View...................................................................................................................11261
Disassembly.........................................................................................................................11261
Inspection and Repair...............................................................................................................11261
Reassembly..........................................................................................................................11262
Main Data and Specifications............................................................................................................11263
Special Tools...........................................................................................................................11266
Sec.8 BODY AND ACCESSORIES....................................................................................................................11299
8A LIGHTING SYSTEM........................................................................................................................11267
Service Precaution......................................................................................................................11267
Headlight Bulb..........................................................................................................................11268
Headlight Assembly......................................................................................................................11268
Headlight Adjustment................................................................................................................11269
Fog Light Bulb..........................................................................................................................11269
Fog Light Assembly......................................................................................................................11270
Fog Light Adjustment................................................................................................................11270
Side Marker Light Bulb..................................................................................................................11270
Taillight Bulb..........................................................................................................................11271
License Plate Light Bulb (Bumper Type)..................................................................................................11271
License Plate Light Bulb (Tailgate Type)................................................................................................11272
Stoplight Bulb..........................................................................................................................11272
High Mounted Stoplight Assembly.........................................................................................................11273
High Mounted Stoplight Bulb.............................................................................................................11273
Backup Light Bulb.......................................................................................................................11274
Front Turn Signal Light Bulb............................................................................................................11274
Rear Turn Signal Light Bulb.............................................................................................................11275
Dome Light Bulb.........................................................................................................................11275
Courtesy Light Bulb.....................................................................................................................11276
Spotlight Bulb..........................................................................................................................11276
Luggage Room Light Bulb.................................................................................................................11277
HVAC Bezel Illumination Light Bulb......................................................................................................11277
Shift Lever Illumination Light Bulb (A/T)...............................................................................................11278
Vanity Mirror Illumination Light Bulb...................................................................................................11278
Starter Switch..........................................................................................................................11279
Lighting Switch (Combination Switch)....................................................................................................11279
Dimmer-Passing Switch (Combination Switch)..............................................................................................11279
Door Switch.............................................................................................................................11279
Rear Defogger Switch....................................................................................................................11280
Key Remind Switch (Starter Switch)......................................................................................................11280
Hazard Warning Light Switch.............................................................................................................11281
Stoplight Switch........................................................................................................................11281
Backup Light Switch.....................................................................................................................11282
Turn Signal Light Switch (Combination Switch)...........................................................................................11282
Illumination Controller.................................................................................................................11283
Light and Bulb Specifications...........................................................................................................11284
8B WIPER / WASHER SYSTEM..................................................................................................................11286
Service Precaution......................................................................................................................11286
Windshield Wiper/Washer System..........................................................................................................11287
General Description.....................................................................................................................11287
Windshield Wiper And Washer Switch......................................................................................................11287
Removal and Installation............................................................................................................11287
Windshield Wiper Motor..................................................................................................................11287
Removal.............................................................................................................................11287
Installation........................................................................................................................11287
Windshield Washer Motor.................................................................................................................11288
Removal.............................................................................................................................11288
Installation........................................................................................................................11288
Windshield Washer Spray Pattern.........................................................................................................11289
Windshield Wiper Linkage................................................................................................................11290
Windshield Wiper Linkage and Associated Parts.......................................................................................11290
Removal.............................................................................................................................11290
Installation........................................................................................................................11290
Windshield Wiper Arm/Blade..............................................................................................................11291
Removal.............................................................................................................................11291
Installation........................................................................................................................11291
Windshield Wiper Blade Rubber...........................................................................................................11292
Removal.............................................................................................................................11292
Installation........................................................................................................................11292
Rear Wiper/Washer System................................................................................................................11293
General Description.....................................................................................................................11293
Rear Wiper and Washer Switch............................................................................................................11293
Removal.............................................................................................................................11293
Installation........................................................................................................................11293
Rear Wiper Motor........................................................................................................................11294
Removal.............................................................................................................................11294
Installation........................................................................................................................11294
Rear Washer Motor.......................................................................................................................11295
Removal.............................................................................................................................11295
Installation........................................................................................................................11295
Alarm and Relay Control Unit............................................................................................................11295
Removal.............................................................................................................................11295
Installation........................................................................................................................11295
Rear Wiper Arm/Blade....................................................................................................................11296
Removal.............................................................................................................................11296
Installation........................................................................................................................11296
Rear Washer Nozzle......................................................................................................................11296
Removal.............................................................................................................................11296
Installation........................................................................................................................11296
Rear Washer Spray Pattern...........................................................................................................11296
Rear Wiper Blade Rubber.................................................................................................................11297
Removal.............................................................................................................................11297
Installation........................................................................................................................11297
Main Data and Specifications............................................................................................................11298
8C ENTERTAINMENT..........................................................................................................................11299
Service Precaution......................................................................................................................11299
Cigarette Lighter.......................................................................................................................11300
General Description.................................................................................................................11300
Removal.............................................................................................................................11300
Installation........................................................................................................................11300
Digital Clock...........................................................................................................................11300
Removal.............................................................................................................................11300
Installation........................................................................................................................11301
Rod Type Antenna........................................................................................................................11301
Removal.............................................................................................................................11301
Installation........................................................................................................................11301
Accessory Socket........................................................................................................................11302
Front Accessory Socket..............................................................................................................11302
Rear Accessory Socket...............................................................................................................11302
Radio...................................................................................................................................11303
Removal.............................................................................................................................11303
Installation........................................................................................................................11303
Speaker.................................................................................................................................11304
Front Speaker.......................................................................................................................11304
Tweeter Assembly....................................................................................................................11304
Rear Speaker........................................................................................................................11304
Horn....................................................................................................................................11305
Removal.............................................................................................................................11305
Installation........................................................................................................................11305
8D WIRING SYSTEM..........................................................................................................................11306
Fuse, Relay and Diode...................................................................................................................11307
Relay / Fuse Box Location...........................................................................................................11307
Relay / Fuse Box (Instrument Panel).................................................................................................11308
Relay / Fuse Box (L4 Engine Room)...................................................................................................11309
Relay / Fuse Box (V6 Engine Room)...................................................................................................11310
Circuit Diagram.........................................................................................................................11311
8E METER AND GAUGE........................................................................................................................11338
Service Precaution......................................................................................................................11338
General Description.....................................................................................................................11338
Meter Assembly..........................................................................................................................11339
General Description.................................................................................................................11339
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights..................................................11339
Table for Meter/Gauge Connector Terminal Connections................................................................................11341
Removal.............................................................................................................................11343
Installation........................................................................................................................11343
Warning Light Bulb and Indicator Light Bulb.............................................................................................11343
Removal.............................................................................................................................11343
Installation........................................................................................................................11343
A/T Shift Indicator Light Bulb..........................................................................................................11344
Removal.............................................................................................................................11344
Installation........................................................................................................................11345
Vehicle Speed Sensor....................................................................................................................11345
Removal.............................................................................................................................11345
Installation........................................................................................................................11345
Fuel Tank Unit..........................................................................................................................11346
Removal.............................................................................................................................11346
Installation........................................................................................................................11346
Main Data and Specifications............................................................................................................11347
8F BODY STRUCTURE.........................................................................................................................11348
Service Precaution......................................................................................................................11349
Frame...................................................................................................................................11349
General Description.................................................................................................................11349
Frame Dimensions (LWB)..............................................................................................................11350
Frame Dimensions (SWB)..............................................................................................................11351
General Description (Bumper)............................................................................................................11352
Front Bumper............................................................................................................................11352
Parts Location......................................................................................................................11352
Removal.............................................................................................................................11353
Installation........................................................................................................................11353
Front Bumper Slider Bracket.............................................................................................................11354
Removal.............................................................................................................................11354
Installation........................................................................................................................11354
Rear Bumper.............................................................................................................................11355
Parts Location (Spare tire mounted tailgate model)..................................................................................11355
Removal.............................................................................................................................11356
Installation........................................................................................................................11356
Parts Location (Spare tire mounted under floor model)...............................................................................11358
Removal.............................................................................................................................11359
Installation........................................................................................................................11359
Rear Bumper Slider......................................................................................................................11360
Removal.............................................................................................................................11360
Installation........................................................................................................................11360
General Description (Sheet Metal).......................................................................................................11361
Engine Hood.............................................................................................................................11361
Parts Location......................................................................................................................11361
Removal.............................................................................................................................11362
Installation........................................................................................................................11362
Engine Hood Lock........................................................................................................................11364
Parts Location......................................................................................................................11364
Removal.............................................................................................................................11364
Installation........................................................................................................................11365
Radiator Grille.........................................................................................................................11366
Parts Location......................................................................................................................11366
Removal.............................................................................................................................11366
Installation........................................................................................................................11367
Front Fender Panel......................................................................................................................11368
Parts Location......................................................................................................................11368
Removal.............................................................................................................................11368
Installation........................................................................................................................11369
Body Mounting...........................................................................................................................11371
Parts Location......................................................................................................................11371
Tightening Torque...................................................................................................................11371
Body Dimension..........................................................................................................................11372
General Description (Body)..............................................................................................................11387
Instrument Panel Assembly...............................................................................................................11387
Parts Location......................................................................................................................11387
Removal.............................................................................................................................11388
Installation........................................................................................................................11390
Front Door Assembly.....................................................................................................................11391
Parts Location......................................................................................................................11391
Removal.............................................................................................................................11391
Installation........................................................................................................................11392
Rear Door Assembly......................................................................................................................11393
Parts Location......................................................................................................................11393
Removal.............................................................................................................................11393
Installation........................................................................................................................11394
Front Window Regulator, Glass and Glass Run.............................................................................................11395
Parts Location......................................................................................................................11395
Removal.............................................................................................................................11396
Installation........................................................................................................................11398
Rear Window Regulator, Glass and Glass Run..............................................................................................11399
Parts Location......................................................................................................................11399
Removal.............................................................................................................................11400
Installation........................................................................................................................11402
Tailgate (LWB)..........................................................................................................................11403
Parts Location......................................................................................................................11403
Removal.............................................................................................................................11404
Installation........................................................................................................................11404
Tailgate (SWB)..........................................................................................................................11406
Parts Location......................................................................................................................11406
Removal.............................................................................................................................11406
Installation........................................................................................................................11407
Rear Hatchgate (LWB)....................................................................................................................11408
Parts Location......................................................................................................................11408
Removal.............................................................................................................................11409
Installation........................................................................................................................11409
Adjustment..........................................................................................................................11411
Tailgate Glass (Resin Top)..............................................................................................................11412
Parts Location......................................................................................................................11412
Removal.............................................................................................................................11412
Installation........................................................................................................................11413
Spare Tire Carrier......................................................................................................................11414
Parts Location......................................................................................................................11414
Removal.............................................................................................................................11414
Installation........................................................................................................................11414
Spare Tire Hanger.......................................................................................................................11415
Parts Location......................................................................................................................11415
Removal.............................................................................................................................11416
Installation........................................................................................................................11416
Windshield..............................................................................................................................11417
Parts Location......................................................................................................................11417
Removal.............................................................................................................................11417
Installation........................................................................................................................11418
Rear Quarter Glass (LWB)................................................................................................................11421
Parts Location......................................................................................................................11421
Removal.............................................................................................................................11421
Installation........................................................................................................................11422
Rear Quarter Glass (Resin Top)..........................................................................................................11423
Parts Location......................................................................................................................11423
Removal.............................................................................................................................11423
Installation........................................................................................................................11423
Side Window Glass (SWB).................................................................................................................11425
Parts Location......................................................................................................................11425
Removal.............................................................................................................................11425
Installation........................................................................................................................11425
Main Data and Specifications............................................................................................................11427
Special Tools...........................................................................................................................11430
8G SEATS..................................................................................................................................11431
Service Precaution......................................................................................................................11431
Front Seat Assembly.....................................................................................................................11432
Front Seat Assembly and Associated Parts............................................................................................11432
Removal.............................................................................................................................11432
Installation........................................................................................................................11434
Rear Seat Assembly (LWB)................................................................................................................11435
Rear Seat Cushion Assembly and Associated Parts.....................................................................................11435
Removal.............................................................................................................................11435
Installation........................................................................................................................11436
Rear Seat Back Assembly and Associated Parts........................................................................................11437
Removal.............................................................................................................................11437
Installation........................................................................................................................11438
Rear Seat Assembly (SWB)................................................................................................................11439
Rear Seat Assembly and Associated Parts.............................................................................................11439
Removal.............................................................................................................................11440
Installation........................................................................................................................11440
Main Data and Specifications............................................................................................................11441
8H SECURITY AND LOCKS.....................................................................................................................11443
Service Precaution......................................................................................................................11443
Front Door Lock Assembly................................................................................................................11444
Front Door Lock Assembly and Associated Parts.......................................................................................11444
Removal.............................................................................................................................11445
Installation........................................................................................................................11446
Front Outside Handle....................................................................................................................11447
Front Outside Handle and Associated Parts...........................................................................................11447
Removal.............................................................................................................................11447
Installation........................................................................................................................11447
Rear Door Lock Assembly.................................................................................................................11448
Rear Door Lock Assembly and Associated Parts........................................................................................11448
Removal.............................................................................................................................11449
Installation........................................................................................................................11449
Rear Outside Handle.....................................................................................................................11451
Rear Outside Handle and Associated Parts............................................................................................11451
Removal.............................................................................................................................11451
Installation........................................................................................................................11451
Tailgate Lock and Hatchgate Lock (LWB)..................................................................................................11452
Tailgate Lock, Hatchgate Lock and Associated Parts..................................................................................11452
Removal.............................................................................................................................11453
Installation........................................................................................................................11453
Tailgate Lock (SWB).....................................................................................................................11454
Tailgate Lock and Associated Parts..................................................................................................11454
Removal.............................................................................................................................11454
Installation........................................................................................................................11455
Key.....................................................................................................................................11456
Key Coding..........................................................................................................................11456
Key Styles..........................................................................................................................11456
Power Door Lock System..................................................................................................................11457
General Description.................................................................................................................11457
Door Lock Key Switch................................................................................................................11457
Front Door Lock Actuator............................................................................................................11457
Rear Door Lock Actuator.............................................................................................................11457
Tailgate Lock Actuator..............................................................................................................11457
Anti-Theft System.......................................................................................................................11457
General Description.................................................................................................................11457
Anti-Theft & Keyless Entry Controller...............................................................................................11457
Anti-Theft Indicator................................................................................................................11458
Anti-Theft Horn.....................................................................................................................11458
Engine Hood Switch..................................................................................................................11459
Anti-theft & Keyless Entry Control Unit/Transmitter Replacement.....................................................................11459
Main Data and Specifications............................................................................................................11460
8I SUNROOF/CONVERTIBLE TOP...............................................................................................................11461
Service Precaution......................................................................................................................11461
Sunroof Glass (LWB).....................................................................................................................11462
Sunroof Glass and Associated Parts..................................................................................................11462
Removal.............................................................................................................................11462
Installation........................................................................................................................11463
Sunroof Glass (SWB).....................................................................................................................11463
Sunroof Glass and Associated Parts..................................................................................................11463
Removal.............................................................................................................................11464
Installation........................................................................................................................11464
Sunroof Deflector (LWB).................................................................................................................11465
Removal.............................................................................................................................11465
Installation........................................................................................................................11465
Sunroof Deflector (SWB).................................................................................................................11466
Parts Location......................................................................................................................11466
Removal.............................................................................................................................11466
Installation........................................................................................................................11466
Sunshade (LWB)..........................................................................................................................11467
Disassembled View...................................................................................................................11467
Removal.............................................................................................................................11467
Installation........................................................................................................................11468
Sunroof Frame Complete Assembly (LWB)...................................................................................................11469
Sunroof Frame Complete Assembly and Associated Parts................................................................................11469
Removal.............................................................................................................................11469
Installation........................................................................................................................11470
Sunroof Switch..........................................................................................................................11470
Removal.............................................................................................................................11470
Installation........................................................................................................................11470
Sunroof Control Unit....................................................................................................................11471
Removal.............................................................................................................................11471
Installation........................................................................................................................11471
Safety Stop Switch......................................................................................................................11471
Removal.............................................................................................................................11471
Installation........................................................................................................................11471
Limit Switch............................................................................................................................11472
Removal.............................................................................................................................11472
Installation........................................................................................................................11472
Sunroof Motor...........................................................................................................................11472
Removal.............................................................................................................................11472
Installation........................................................................................................................11472
Soft Top Assembly.......................................................................................................................11473
Soft Top Assembly and Associated Parts..............................................................................................11473
Removal.............................................................................................................................11474
Installation........................................................................................................................11474
Resin Top Assembly......................................................................................................................11475
Resin Top Assembly and Associated Parts.............................................................................................11475
Removal.............................................................................................................................11475
Installation........................................................................................................................11476
Seat Belt Cross Bar Assembly............................................................................................................11477
Seat Belt Cross Bar Assembly and Associated Parts...................................................................................11477
Removal.............................................................................................................................11477
Installation........................................................................................................................11478
Main Data and Specifications............................................................................................................11479
8J EXTERIOR / INTERIOR TRIM...............................................................................................................11480
Service Precaution......................................................................................................................11481
Consoles................................................................................................................................11482
Consoles and Associated Parts.......................................................................................................11482
Removal.............................................................................................................................11482
Installation........................................................................................................................11482
Front Door Trim Panel...................................................................................................................11483
Front Door Trim Panel and Associated Parts..........................................................................................11483
Removal.............................................................................................................................11484
Installation........................................................................................................................11484
Rear Door Trim Panel....................................................................................................................11485
Rear Door Trim Panel and Associated Parts...........................................................................................11485
Removal.............................................................................................................................11485
Installation........................................................................................................................11486
Door Mirror Assembly....................................................................................................................11487
Removal.............................................................................................................................11487
Installation........................................................................................................................11487
Interior Trim Panels (LWB)..............................................................................................................11488
Interior Trim Panels and Associated Parts...........................................................................................11488
Removal.............................................................................................................................11488
Installation........................................................................................................................11490
Interior Trim Panels (SWB)..............................................................................................................11491
Interior Trim Panels and Associated Parts...........................................................................................11491
Removal.............................................................................................................................11491
Installation........................................................................................................................11492
Headlining (LWB)........................................................................................................................11493
Parts Location......................................................................................................................11493
Removal.............................................................................................................................11493
Installation........................................................................................................................11494
Headlining (SWB)........................................................................................................................11495
Parts Location......................................................................................................................11495
Removal.............................................................................................................................11496
Installation........................................................................................................................11497
Wheel Arch Protector (LWB)..............................................................................................................11498
Wheel Arch Protector and Associated Parts...........................................................................................11498
Removal.............................................................................................................................11498
Installation........................................................................................................................11498
Wheel Arch Protector (SWB)..............................................................................................................11499
Wheel Arch Protector and Associated Parts...........................................................................................11499
Removal.............................................................................................................................11499
Installation........................................................................................................................11499
Wheel Arch Molding (SWB)................................................................................................................11500
Wheel Arch Molding and Associated Parts.............................................................................................11500
Removal.............................................................................................................................11500
Installation........................................................................................................................11501
Wheel Arch Molding (LWB)................................................................................................................11502
Wheel Arch Molding and Associated Parts.............................................................................................11502
Removal.............................................................................................................................11502
Installation........................................................................................................................11503
Fuel Filler Door........................................................................................................................11504
Parts Location......................................................................................................................11504
Removal.............................................................................................................................11504
Installation........................................................................................................................11504
Roof Rail...............................................................................................................................11505
Parts Location......................................................................................................................11505
Removal.............................................................................................................................11505
Installation........................................................................................................................11505
Power Door Mirror System................................................................................................................11506
General Description.................................................................................................................11506
Door Mirror Switch..................................................................................................................11506
Power Window System.....................................................................................................................11507
General Description.................................................................................................................11507
Power Window Switch Driver Seat Side................................................................................................11507
Power Window Motor..................................................................................................................11508
Main Data and Specifications............................................................................................................11509
Sec.9 RESTRAINTS..............................................................................................................................11561
9A SEAT BELT SYSTEM......................................................................................................................11510
Service Precaution......................................................................................................................11510
Front Seat Belt (LWB)...................................................................................................................11511
Front Seat Belt and Associated Parts................................................................................................11511
Removal.............................................................................................................................11511
Inspection..........................................................................................................................11511
Installation........................................................................................................................11512
Front Seat Belt (SWB)...................................................................................................................11513
Front Seat Belt and Associated Parts................................................................................................11513
Removal.............................................................................................................................11513
Inspection..........................................................................................................................11514
Installation........................................................................................................................11514
Rear Seat Belt (LWB)....................................................................................................................11515
Rear Seat Belt and Associated Parts.................................................................................................11515
Removal.............................................................................................................................11515
Inspection..........................................................................................................................11516
Installation........................................................................................................................11516
Rear Seat Belt (SWB)....................................................................................................................11517
Rear Seat Belt and Associated Parts.................................................................................................11517
Removal.............................................................................................................................11517
Inspection..........................................................................................................................11519
Installation........................................................................................................................11519
Front Seat Buckle Assembly..............................................................................................................11520
Removal.............................................................................................................................11520
Installation........................................................................................................................11520
Rear Center Seat Belt / Buckle Assembly.................................................................................................11521
Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................11521
Removal.............................................................................................................................11521
Installation........................................................................................................................11521
Child Seat Tether Anchor Bracket (Child Restraint)......................................................................................11522
General Description.................................................................................................................11522
Child Seat Tether Anchor Bracket and Associated Parts...............................................................................11522
Installation........................................................................................................................11522
Main Data and Specifications............................................................................................................11523
9J SEAT BELT SYSTEM......................................................................................................................11525
Service Precaution......................................................................................................................11526
General Description.....................................................................................................................11526
Restraint Devices...................................................................................................................11526
System Description..................................................................................................................11527
SRS Component and Wiring Location View..................................................................................................11528
Component Description...............................................................................................................11528
SDM (Sensing and Diagnostic Module).................................................................................................11528
"Air Bag" Warning Lamp..............................................................................................................11529
SRS Coil Assembly...................................................................................................................11529
Air Bag Assemblies..................................................................................................................11529
Steering Column.....................................................................................................................11530
Knee Bolster........................................................................................................................11530
Definition..............................................................................................................................11530
Diagnosis...............................................................................................................................11531
Diagnostic Trouble Codes............................................................................................................11531
Scan Tool Diagnostics...............................................................................................................11531
Use of Special Tools................................................................................................................11532
SRS Connector Body Face Views...........................................................................................................11532
Repairs and Inspections Required After an Accident......................................................................................11532
Accident With Deployment - Component Replacement and Inspections....................................................................11533
Accident With or Without Deployment佑omponent Inspection.............................................................................11533
SDM Replacement Guidelines..........................................................................................................11533
Wiring Damage.......................................................................................................................11533
SRS Connector (Plastic Body And Terminal Metal Pin) Damage..........................................................................11533
SRS Wire Pigtail Damage.............................................................................................................11533
On-Vehicle Service......................................................................................................................11533
Service Precautions.................................................................................................................11533
Disabling The SRS...................................................................................................................11533
Enabling The SRS....................................................................................................................11533
Handling / Installation / Diagnosis.................................................................................................11534
Air Bag Assembly Handling / Shipping / Scrapping........................................................................................11534
Live (Undeployed) Air Bag Assembly..................................................................................................11534
Air Bag Assembly Shipping Procedure For Live (Undeployed) Air Bag Assemblies........................................................11535
Deployed Air Bag Assembly...........................................................................................................11535
Air Bag Assembly Scrapping Procedure................................................................................................11535
Deployment Outside Vehicle (Driver Air Bag Assembly)................................................................................11535
Deployment Outside Vehicle (Passenger Air Bag Assembly).............................................................................11537
Deployment Inside Vehicle (Vehicle Scrapping Procedure).............................................................................11539
Deployed Air Bag Assembly Handling..................................................................................................11542
Special Tools...........................................................................................................................11542
J-41433 SRS Driver/Passenger Load Tool..............................................................................................11542
J-39200 DVM.........................................................................................................................11543
Scan Tool...........................................................................................................................11543
J-35616-A Connector Test Adapter Kit................................................................................................11543
J-42986 SRS Deployment Tool.........................................................................................................11543
J-42987 SRS Adapter For Load Tool...................................................................................................11544
J-41497 SRS Deployment Fixture......................................................................................................11544
Tech 2 Scan Tool....................................................................................................................11545
DTC Modes...........................................................................................................................11548
Plottong Snapshot Graph.................................................................................................................11548
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)......................................................11549
Flow Chart for Snapshot Replay (Plotting Graph).....................................................................................11550
Service Precaution......................................................................................................................11551
Disabling The SRS...................................................................................................................11551
Enabling The SRS....................................................................................................................11551
Handling / Installation / Diagnosis.................................................................................................11551
Inspections Required After An Accident..............................................................................................11551
Sensing and Diagnostic Module (SDM).....................................................................................................11552
Service Precautions.................................................................................................................11552
Removal.............................................................................................................................11552
Installation........................................................................................................................11553
Driver Air Bag Assembly.................................................................................................................11553
Service Precautions.................................................................................................................11553
Removal.............................................................................................................................11553
Installation........................................................................................................................11554
Steering Wheel..........................................................................................................................11554
Service Precautions.................................................................................................................11554
Removal.............................................................................................................................11554
Installation........................................................................................................................11555
SRS Coil Assembly.......................................................................................................................11556
Service Precaution..................................................................................................................11556
Removal.............................................................................................................................11556
Installation........................................................................................................................11556
Steering Column.........................................................................................................................11558
Service Precaution..................................................................................................................11558
Removal.............................................................................................................................11558
Installation........................................................................................................................11559
Passenger Air Bag Assembly..............................................................................................................11560
Service Precaution..................................................................................................................11560
Removal.............................................................................................................................11560
Installation........................................................................................................................11560
9J1 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)...................................................................................................11561
Service Precaution......................................................................................................................11561
Diagnostic Information..................................................................................................................11562
Diagnostic Procedures...............................................................................................................11562
Diagnostic Codes....................................................................................................................11562
How To Read Trouble Codes...........................................................................................................11562
How To Clear Trouble Codes..........................................................................................................11562
Scan Tool Diagnostics...............................................................................................................11562
Basic Knowledge Required............................................................................................................11562
Basic Electrical Circuits...........................................................................................................11562
"Flash Code" Diagnostics............................................................................................................11562
System Schematic........................................................................................................................11563
SRS Diagnostic System Check.............................................................................................................11564
Chart A SDM Integrity Check.............................................................................................................11566
Chart B "AIR BAG" Warning Lamp Comes "ON" Steady........................................................................................11568
Chart C "AIR BAG" Warning Lamp Does Not Comes "ON" Steady...............................................................................11570
DTC 15 Passenger Deployment Loop Resistance High........................................................................................11573
DTC 16 Passenger Deployment Loop Resistance Low.........................................................................................11576
DTC 17 Passenger Deployment Loop Open...................................................................................................11579
DTC 18 Passenger Deployment Loop Short To Ground........................................................................................11581
DTC 19 Passenger Deployment Loop Short To Voltage.......................................................................................11583
DTC 21 Driver Deployment Loop Resistance High...........................................................................................11585
DTC 22 Driver Deployment Loop Resistance Low............................................................................................11588
DTC 24 Driver Deployment Loop Short To Ground...........................................................................................11591
DTC 25 Driver Deployment Loop Short To Voltage..........................................................................................11593
DTC 26 Driver Deployment Loop Open......................................................................................................11596
DTC 51 Deployment Event Commanded.......................................................................................................11599
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range..................................................11601
DTC 61 Warning Lamp Circuit Failure.....................................................................................................11603
DTC 71 Internal SDM Fault...............................................................................................................11605
Sec.10 CONTROL SYSTEM..........................................................................................................................11607
10A CRUISE CONTROL SYSTEM.................................................................................................................11607
Service Precaution......................................................................................................................11607
General Description.....................................................................................................................11607
Brake Switch............................................................................................................................11608
Removal and Installation............................................................................................................11608
Adjustment..........................................................................................................................11608
Clutch Switch...........................................................................................................................11609
Removal and Installation............................................................................................................11609
Adjustment..........................................................................................................................11609
Powertrain Control Module (PCM) Removal and Installation................................................................................11609
Mode Switch Removal and Installation................................................................................................11609
Cruise Control Main Switch..............................................................................................................11610
Removal.............................................................................................................................11610
Installation........................................................................................................................11610
Cruise Control Switch (Combination Switch)..............................................................................................11610
Removal and Installation............................................................................................................11610
Diagnosis...............................................................................................................................11611
(UA) AMIGO..........................................................................................................................................11612
Sec.0 GENERAL INFORMATION.....................................................................................................................11628
0A GENERAL INFORMATION.....................................................................................................................11613
General Repair Instruction..............................................................................................................11613
Illustration Arrows.....................................................................................................................11614
Identification..........................................................................................................................11615
Theft Prevention Standard...............................................................................................................11618
Lifting Instructions....................................................................................................................11623
Standard Bolts Torque Specifications....................................................................................................11625
Abbreviations Charts....................................................................................................................11626
Service Parts Identification Plate......................................................................................................11627
0B MAINTENANCE AND LUBRICATION.............................................................................................................11628
Maintenance Schedule List...............................................................................................................11628
Explanation of Complete Vehicle Maintenance Schedule....................................................................................11632
Recommended Fluids and Lubricants...................................................................................................11635
Lubricant Viscosity Chart...............................................................................................................11636
Recommended Liquid Gasket...........................................................................................................11638
Recommended Thread Locking Agents...................................................................................................11638
Maintenance Service Data................................................................................................................11639
Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................................................11640
1A HVAC SYSTEMS...........................................................................................................................11640
Sec.2 STEERING................................................................................................................................11641
2A POWER-ASSISTED STEERING SYSTEM.........................................................................................................11641
Service Precaution......................................................................................................................11642
Diagnosis...............................................................................................................................11642
General Description.....................................................................................................................11648
Power Steering System Test..............................................................................................................11650
Maintenance.............................................................................................................................11651
Fluid Level.............................................................................................................................11651
Bleeding The Power Steering System......................................................................................................11651
Bleeding Procedure......................................................................................................................11651
Flushing The Power Steering System......................................................................................................11651
Steering Wheel Free Play Inspection.....................................................................................................11652
Front End Alignment Inspection and Adjustment...........................................................................................11652
Main Data and Specifications............................................................................................................11656
Special Tools...........................................................................................................................11657
Power Steering Unit.....................................................................................................................11658
Power Steering Unit and Associated Parts............................................................................................11658
Removal.............................................................................................................................11658
Installation (4 × 2 Model)..........................................................................................................11659
Installation (4 × 4 Model)..........................................................................................................11659
Power Steering Unit Disassembled View...............................................................................................11660
Disassembly.........................................................................................................................11660
Inspection and Repair...............................................................................................................11660
Reassembly..........................................................................................................................11660
Main Data and Specifications........................................................................................................11661
Special Tools.......................................................................................................................11661
Power Steering Pump.....................................................................................................................11662
Power Steering Pump and Associated Parts............................................................................................11662
Removal.............................................................................................................................11662
Installation........................................................................................................................11662
Power Steering Pump Disassembled View...............................................................................................11663
Disassembly.........................................................................................................................11663
Inspection and Repair...............................................................................................................11664
Reassembly..........................................................................................................................11664
Main Data and Specifications........................................................................................................11666
Transfer Gear Assembly..................................................................................................................11667
Transfer Gear Assembly and Associated Parts.........................................................................................11667
Removal.............................................................................................................................11667
Inspection and Repair...............................................................................................................11667
Installation........................................................................................................................11667
Supplemental Restraint System Steering Wheel & Column...................................................................................11668
Service Precaution..................................................................................................................11668
Inflator Module.........................................................................................................................11669
Inflator Module and Associated Parts................................................................................................11669
Removal.............................................................................................................................11669
Inspection and Repair...............................................................................................................11670
Installation........................................................................................................................11670
Steering Wheel..........................................................................................................................11671
Steering Wheel and Associated Parts.................................................................................................11671
Removal.............................................................................................................................11671
Installation........................................................................................................................11673
Combination Switch......................................................................................................................11674
Combination Switch and Associated Parts.............................................................................................11674
Removal.............................................................................................................................11674
Installation........................................................................................................................11676
Lock Cylinder...........................................................................................................................11678
Lock Cylinder and Associated Parts..................................................................................................11678
Removal.............................................................................................................................11678
Installation........................................................................................................................11680
System Inspection...................................................................................................................11681
Steering Column.........................................................................................................................11682
Steering Column and Associated Parts................................................................................................11682
Removal.............................................................................................................................11682
Installation........................................................................................................................11684
System Inspection...................................................................................................................11685
Supplemental Restraint System Steering Wheel & Column and Associated Parts..............................................................11686
Main Data and Specifications........................................................................................................11686
Special Tools.......................................................................................................................11686
Sec.3 SUSPENSION..............................................................................................................................11687
3C FRONT SUSPENSION.......................................................................................................................11687
Service Precaution......................................................................................................................11687
General Description.....................................................................................................................11688
Diagnosis...............................................................................................................................11688
Shock Absorber..........................................................................................................................11691
Shock Absorber and Associated Parts.................................................................................................11691
Removal.............................................................................................................................11691
Inspection and Repair...............................................................................................................11691
Installation........................................................................................................................11691
Stabilizer Bar..........................................................................................................................11692
Stabilizer Bar and Associated Parts.................................................................................................11692
Removal.............................................................................................................................11692
Inspection and Repair...............................................................................................................11692
Installation........................................................................................................................11692
Torsion Bar.............................................................................................................................11693
Torsion Bar and Associated Parts....................................................................................................11693
Removal.............................................................................................................................11693
Inspection and Repair...............................................................................................................11694
Installation........................................................................................................................11694
Knuckle.................................................................................................................................11696
Knuckle and Associated Parts........................................................................................................11696
Removal.............................................................................................................................11696
Inspection and Repair...............................................................................................................11697
Installation........................................................................................................................11697
Upper Control Arm.......................................................................................................................11699
Upper Control Arm and Associated Parts..............................................................................................11699
Removal.............................................................................................................................11699
Inspection and Repair...............................................................................................................11700
Installation........................................................................................................................11700
Lower Control Arm.......................................................................................................................11702
Lower Control Arm and Associated Parts..............................................................................................11702
Removal.............................................................................................................................11702
Inspection and Repair...............................................................................................................11703
Installation........................................................................................................................11704
Upper Ball Joint........................................................................................................................11705
Upper Ball Joint and Associated Parts...............................................................................................11705
Removal.............................................................................................................................11705
Inspection and Repair...............................................................................................................11706
Installation........................................................................................................................11706
Lower Ball Joint........................................................................................................................11707
Lower Ball Joint and Associated Parts...............................................................................................11707
Removal.............................................................................................................................11707
Inspection and Repair...............................................................................................................11708
Installation........................................................................................................................11708
Main Data and Specifications............................................................................................................11709
Special Tools...........................................................................................................................11710
3D REAR SUSPENSION........................................................................................................................11711
Service Precaution......................................................................................................................11711
General Description.....................................................................................................................11711
Diagnosis...............................................................................................................................11712
Coil Spring.............................................................................................................................11715
Coil Spring and Associated Parts....................................................................................................11715
Removal.............................................................................................................................11715
Inspection and Repair...............................................................................................................11716
Installation........................................................................................................................11716
Shock Absorber..........................................................................................................................11717
Shock Absorber and Associated Parts.................................................................................................11717
Removal.............................................................................................................................11717
Inspection and Repair...............................................................................................................11717
Installation........................................................................................................................11717
Trailing Link...........................................................................................................................11718
Trailing Link and Associated Parts..................................................................................................11718
Removal.............................................................................................................................11718
Inspection and Repair...............................................................................................................11718
Installation........................................................................................................................11719
Upper Link..............................................................................................................................11720
Upper Link and Associated Parts.....................................................................................................11720
Removal.............................................................................................................................11720
Inspection and Repair...............................................................................................................11720
Installation........................................................................................................................11721
Lateral Rod.............................................................................................................................11722
Lateral Rod and Associated Parts....................................................................................................11722
Removal.............................................................................................................................11722
Inspection and Repair...............................................................................................................11722
Installation........................................................................................................................11723
Stabilizer Bar..........................................................................................................................11724
Stabilizer Bar and Associated Parts.................................................................................................11724
Removal.............................................................................................................................11724
Inspection and Repair...............................................................................................................11724
Installation........................................................................................................................11725
Main Data and Specifications............................................................................................................11725
Special Tools...........................................................................................................................11727
3E WHEEL AND TIRE SYSTEM..................................................................................................................11728
3F INTELLIGENT SUSPENSION SYSTEM..........................................................................................................11729
Service Precaution......................................................................................................................11730
General Description.....................................................................................................................11730
PIN ASSIGNMENT TABLE................................................................................................................11732
System Components...................................................................................................................11732
Control Unit........................................................................................................................11732
Actuator............................................................................................................................11732
Adjustable Damping Force Shock Absorber.............................................................................................11732
Warning Lamp........................................................................................................................11732
Vertical G-Sensor...................................................................................................................11733
Horizontal G-Sensor.................................................................................................................11733
Acronyms and Abbreviations..........................................................................................................11733
General Diagnosis.......................................................................................................................11733
General Information.................................................................................................................11733
Service Precautions.................................................................................................................11733
Computer System Service Precautions.................................................................................................11733
General Service Precautions.........................................................................................................11733
Parts Handling......................................................................................................................11733
FLASHING CODES......................................................................................................................11734
CLEAR DTC...........................................................................................................................11735
INTERMITTENT CONDITIONS.............................................................................................................11736
BULB CHECK..........................................................................................................................11736
DTC CHECK...........................................................................................................................11736
Basic Diagnosis Flow................................................................................................................11737
Circuit Diagram.....................................................................................................................11738
Parts Location......................................................................................................................11741
Connector List......................................................................................................................11742
Diagnostic Trouble Code (DTC) Identification........................................................................................11744
DTC2 Actuator Coil Over Current.........................................................................................................11745
Circuit Description.................................................................................................................11745
Diagnostic Aids.....................................................................................................................11745
DTC3 Actuator Coil/Position Sensor Open Circuit or Short................................................................................11747
Circuit Description.................................................................................................................11747
Diagnostic Aids.....................................................................................................................11747
DTC4 G-Sensor Open Circuit or Short.....................................................................................................11750
Circuit Description.................................................................................................................11750
Diagnostic Aids.....................................................................................................................11750
DTC5 Vehicle Speed Sensor Open Circuit or Short.........................................................................................11751
Circuit Description.................................................................................................................11751
Diagnostic Aids.....................................................................................................................11751
DTC6 Stop Lamp Switch Open Circuit or Short.............................................................................................11753
Circuit Description.................................................................................................................11753
Diagnostic Aids.....................................................................................................................11753
DTC7 Engine Speed Signal Open Circuit or Short..........................................................................................11755
Circuit Description.................................................................................................................11755
Diagnostic Aids.....................................................................................................................11755
DTC9 Control Unit Abnormality.......................................................................................................11756
Control Unit............................................................................................................................11760
Control Unit and Associated Parts...................................................................................................11760
Removal.............................................................................................................................11760
Installation........................................................................................................................11761
Front Actuator..........................................................................................................................11762
Front Actuator and Associated Parts.................................................................................................11762
Removal.............................................................................................................................11763
Inspection and Repair...............................................................................................................11763
Installation........................................................................................................................11763
Rear Shock Absorber.....................................................................................................................11764
Rear Shock Absorber and Associated Parts............................................................................................11764
Removal.............................................................................................................................11765
Inspection and Repair...............................................................................................................11765
Installation........................................................................................................................11765
Sec.4 DRIVELINE/AXLE..........................................................................................................................11766
4A1 DIFFERENTIAL (FRONT)..................................................................................................................11766
Main Data And Specifications............................................................................................................11767
4A2 DIFFERENTIAL (REAR)...................................................................................................................11768
Main Data And Specifications............................................................................................................11769
4B DRIVELINE CONTROL SYSTEM..............................................................................................................11770
4C DRIVE SHAFT SYSTEM....................................................................................................................11771
Service Precaution......................................................................................................................11772
Front Propeller Shaft...................................................................................................................11773
General Description.................................................................................................................11773
Diagnosis of Propeller Shaft and Universal Joint....................................................................................11775
Front Propeller Shaft and Associated Parts..........................................................................................11776
Removal.............................................................................................................................11776
Installation........................................................................................................................11776
Slip Joint Disassembly..............................................................................................................11777
Universal Joint Disassembly(Single Cardan Type).....................................................................................11778
Universal Joint Reassembly(Single Cardan Type)......................................................................................11780
Slip Joint Reassembly...............................................................................................................11782
Main Data And Specifications........................................................................................................11783
Rear Propeller Shaft....................................................................................................................11784
General Description.................................................................................................................11784
Diagnosis of Propeller Shaft and Universal Joint....................................................................................11786
Rear Propeller Shaft and Associated Parts...........................................................................................11787
Removal.............................................................................................................................11787
Installation........................................................................................................................11787
Slip Joint Disassembly (6VD1 Model Only)............................................................................................11788
Universal Joint Disassembly.........................................................................................................11789
Inspection..........................................................................................................................11791
Universal Joint Reassembly..........................................................................................................11792
Slip Joint Reassembly (6VD1 Model Only).............................................................................................11793
Main Data and Specifications........................................................................................................11794
4D TRANSFER CASE.........................................................................................................................11795
Sec.5 BRAKE...................................................................................................................................11796
5A BRAKE CONTROL SYSTEM..................................................................................................................11796
5B ANTI-LOCK BRAKE SYSTEM................................................................................................................11796
5C POWER-ASSISTED BRAKE SYSTEM...........................................................................................................11796
5D1 PARKING BRAKE SYSTEM (4x4 Model)......................................................................................................11796
5D2 PARKING BRAKE SYSTEM (4x2 Model)......................................................................................................11796
Sec.6 ENGINE..................................................................................................................................11797
X22SE 2.2L ENGINE...........................................................................................................................11797
6A ENGINE MECHANICAL..................................................................................................................11797
6B ENGINE COOLING.....................................................................................................................11797
6C ENGINE FUEL........................................................................................................................11797
6D1 ENGINE ELECTRICAL..................................................................................................................11797
6D2 IGNITION SYSTEM....................................................................................................................11797
6D3 STARTING AND CHARGING SYSTEM.......................................................................................................11797
6E1 DRIVEABILITY AND EMISSIONS.........................................................................................................11797
6F ENGINE EXHAUST.....................................................................................................................11797
6G ENGINE LUBRICATION.................................................................................................................11797
6H ENGINE SPEED CONTROL SYSTEM........................................................................................................11797
6J INDUCTION..........................................................................................................................11797
6VD1 3.2L ENGINE...........................................................................................................................11797
6A ENGINE MECHANICAL..................................................................................................................11797
6B ENGINE COOLING.....................................................................................................................11797
6C ENGINE FUEL........................................................................................................................11797
6D1 ENGINE ELECTRICAL..................................................................................................................11797
6D2 IGNITION SYSTEM....................................................................................................................11797
6D3 STARTING AND CHARGING SYSTEM.......................................................................................................11797
6E2 DRIVEABILITY AND EMISSIONS.........................................................................................................11797
6F ENGINE EXHAUST.....................................................................................................................11797
6G ENGINE LUBRICATION.................................................................................................................11797
6H ENGINE SPEED CONTROL SYSTEM........................................................................................................11797
6J INDUCTION..........................................................................................................................11797
Sec.7 AUTOMATIC TRANSMISSION..................................................................................................................11798
7B MANUAL TRANSMISSION MUA 5C..............................................................................................................11798
7C CLUTCH..................................................................................................................................11798
Sec.8 LIGHTING SYSTME.........................................................................................................................11799
8A LIGHTING SYSTEM........................................................................................................................11799
8B WIPER / WASHER SYSTEM..................................................................................................................11799
8C ENTERTAINMENT..........................................................................................................................11799
8D WIRING SYSTEM..........................................................................................................................11799
8E METER AND GAUGE........................................................................................................................11799
8F BODY STRUCTURE.........................................................................................................................11799
8G SEATS..................................................................................................................................11799
8H SECURITY AND LOCKS.....................................................................................................................11799
8I SUNROOF/CONVERTIBLE TOP...............................................................................................................11799
8J EXTERIOR / INTERIOR TRIM...............................................................................................................11799
Sec.9 SEAT BELT SYSTEM........................................................................................................................11800
9A SEAT BELT SYSTEM......................................................................................................................11800
9J SEAT BELT SYSTEM......................................................................................................................11800
9J1 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)...................................................................................................11800
Sec.10 CRUISE CONTROL SYSTEM...................................................................................................................11801
10A CRUISE CONTROL SYSTEM.................................................................................................................11801
(VX) VEHICROSS......................................................................................................................................11802
Sec.0 GENERAL INFORMATION.....................................................................................................................11803
0A GENERAL INFORMATION....................................................................................................................11803
General Repair Instruction..............................................................................................................11803
Illustration Arrows.....................................................................................................................11804
Identification..........................................................................................................................11805
Theft Prevention Standard...............................................................................................................11807
Lifting Instructions....................................................................................................................11811
Standard Bolts Torque Specifications....................................................................................................11814
Abbreviations Charts....................................................................................................................11815
Service Parts Identification Plate......................................................................................................11816
0B MAINTENANCE AND LUBRICATION............................................................................................................11817
Maintenance Schedule List...............................................................................................................11817
Explanation of Complete Vehicle Maintenance Schedule....................................................................................11820
Recommended Fluids and Lubricants...................................................................................................11823
Lubricant Viscosity Chart...............................................................................................................11824
Recommended Thread Locking Agents.......................................................................................................11826
Maintenance Service Data................................................................................................................11827
Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................................................11828
1A HVAC SYSTEMS...........................................................................................................................11828
Service Precaution......................................................................................................................11830
Heating and Ventilation System..........................................................................................................11830
General Description.................................................................................................................11830
Wiring Diagram......................................................................................................................11834
Diagnosis...........................................................................................................................11835
Individual Inspection...............................................................................................................11839
Heater Unit.............................................................................................................................11841
Heater Unit and Associated Parts....................................................................................................11841
Removal.............................................................................................................................11841
Installation........................................................................................................................11842
Heater Core and / or Mode Door..........................................................................................................11842
Disassembled View...................................................................................................................11842
Removal.............................................................................................................................11843
Inspection..........................................................................................................................11843
Installation........................................................................................................................11843
Heater Mode Control Link Unit...........................................................................................................11844
Disassembled View...................................................................................................................11844
Removal.............................................................................................................................11844
Installation........................................................................................................................11845
Heater Temperature Control Link Unit....................................................................................................11845
Disassembled View...................................................................................................................11845
Removal.............................................................................................................................11845
Installation........................................................................................................................11845
Blower Assembly.........................................................................................................................11846
Blower Assembly and Associated Parts................................................................................................11846
Removal.............................................................................................................................11846
Installation........................................................................................................................11847
Blower Link Unit and / or Mode door.....................................................................................................11847
Disassembled View...................................................................................................................11847
Removal.............................................................................................................................11847
Installation........................................................................................................................11848
Blower Motor............................................................................................................................11849
Blower Motor and Associated Parts...................................................................................................11849
Removal.............................................................................................................................11849
Installation........................................................................................................................11849
Defroster Nozzle and Ventilation Duct...................................................................................................11850
Defroster Nozzle, Ventilation Duct and Associated Parts.............................................................................11850
Removal.............................................................................................................................11850
Installation........................................................................................................................11851
Control Lever Assembly and / or Control Cable...........................................................................................11851
Control Lever Assembly, Control Cable and Associated Parts..........................................................................11851
Removal.............................................................................................................................11852
Installation........................................................................................................................11853
Heater Bezel Illumination Bulb..........................................................................................................11854
Heater Bezel Illumination Bulb and Associated Parts.................................................................................11854
Removal.............................................................................................................................11854
Installation........................................................................................................................11854
Resistor................................................................................................................................11855
Resistor and Associated Parts.......................................................................................................11855
Removal.............................................................................................................................11855
Installation........................................................................................................................11855
Air Conditioning System.................................................................................................................11856
General Description.................................................................................................................11856
Air Conditioning Refrigerant Cycle Construction.....................................................................................11857
Wiring Diagram......................................................................................................................11864
Connector List......................................................................................................................11868
Diagnosis...........................................................................................................................11870
Individual Inspection...............................................................................................................11880
General Repair Procedure............................................................................................................11881
Leak Check..........................................................................................................................11884
Compressor Assembly.....................................................................................................................11889
Compressor Assembly and Associated Parts............................................................................................11889
Removal.............................................................................................................................11889
Installation........................................................................................................................11890
New Compressor Installation.........................................................................................................11890
Condenser Assembly......................................................................................................................11891
Condenser Assembly and Associated Parts.............................................................................................11891
Removal.............................................................................................................................11891
Installation........................................................................................................................11891
Condenser Fan Motor.....................................................................................................................11892
Condenser Fan Motor and Associated Parts............................................................................................11892
Removal.............................................................................................................................11893
Installation........................................................................................................................11893
Receiver / Drier........................................................................................................................11893
Receiver / Drier and Associated Parts...............................................................................................11893
Removal.............................................................................................................................11893
Installation........................................................................................................................11893
Pressure Switch.........................................................................................................................11894
Pressure Switch and Associated Parts................................................................................................11894
Removal.............................................................................................................................11894
Installation........................................................................................................................11894
Evaporator Assembly.....................................................................................................................11895
Evaporator Assembly and Associated Parts............................................................................................11895
Removal.............................................................................................................................11895
Installation........................................................................................................................11896
Electronic Thermostat, Evaporator Core and/or Expansion Valve...........................................................................11896
Disassembled View...................................................................................................................11896
Removal.............................................................................................................................11897
Installation........................................................................................................................11897
Refrigerant Line........................................................................................................................11898
Refrigerant Line and Associated Parts...............................................................................................11898
Removal.............................................................................................................................11899
Installation........................................................................................................................11899
Main Data And Specifications............................................................................................................11900
Compressor..............................................................................................................................11903
Service Precaution..................................................................................................................11903
General Description.................................................................................................................11903
Diagnosis...........................................................................................................................11904
Magnetic Clutch Assembly (DKV-14D Type).................................................................................................11905
Parts Location View.................................................................................................................11905
Removal.............................................................................................................................11905
Inspection and Repair...............................................................................................................11907
Installation........................................................................................................................11907
Compressor Oil..........................................................................................................................11909
Oil Specification...................................................................................................................11909
Handling of Oil.....................................................................................................................11909
Compressor Oil Check................................................................................................................11909
Checking and Adjusting Oil Quantity for Used Compressor.............................................................................11909
Checking and Adjusting for Compressor Replacement...................................................................................11910
Contamination of Compressor Oil.....................................................................................................11910
Oil Return Operation................................................................................................................11910
Replacement of Component Parts......................................................................................................11910
Main Data and Specifications............................................................................................................11911
Special Tools...........................................................................................................................11913
Automatic Air Conditioning System.......................................................................................................11914
General Description.................................................................................................................11914
Full Automatic Air Conditioner Parts Configuration..................................................................................11914
Refrigerant Line and Associated Parts...............................................................................................11915
Circuit Diagram.....................................................................................................................11916
Functions and Features..............................................................................................................11921
Automatic Air Conditioner Block Diagram.............................................................................................11922
Control Panel Layout................................................................................................................11923
Air Control Functions...............................................................................................................11924
Operation and Functions of Control Panel Switches...................................................................................11925
Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System..................................11927
Overview of Automatic Control of Automatic Air Conditioner..........................................................................11931
Troubleshooting, Its Overview and Procedures............................................................................................11935
Auto Air Conditioner Control Unit Power Supply Diagnosis................................................................................11936
Performance and Movement checklist for Automatic Air Conditioner Related Parts..........................................................11938
Troubleshooting With Self-Diagnosis Function............................................................................................11940
Inspection By Failed Location...........................................................................................................11944
Inspection of the Sensors...........................................................................................................11944
Inspection of the Intake Actuator System................................................................................................11948
Inspection of the Mix Actuator System...................................................................................................11951
Inspection of the Mode Actuator System..................................................................................................11954
Inspection of the Fan Motor System......................................................................................................11957
Inspection of the Magnetic Clutch System................................................................................................11962
Individual Inspection...................................................................................................................11965
On-Vehicle Service......................................................................................................................11968
Power Transistor....................................................................................................................11968
Automatic Heater/Air Conditioner Control Unit.......................................................................................11968
In Car Sensor.......................................................................................................................11969
Ambient Sensor......................................................................................................................11969
Sun Sensor..........................................................................................................................11970
Electronic Thermostat...............................................................................................................11970
Mode Actuator.......................................................................................................................11971
Mix Actuator........................................................................................................................11971
Intake Actuator.....................................................................................................................11972
Sec.2 STEERING................................................................................................................................11973
2A POWER ASSISTED SYSTEM...................................................................................................................11973
Service Precaution......................................................................................................................11974
General Description.....................................................................................................................11974
Diagnosis...............................................................................................................................11977
Power Steering System Test..............................................................................................................11983
Maintenance.............................................................................................................................11983
Fluid Level.............................................................................................................................11984
Bleeding The Power Steering System......................................................................................................11984
Bleeding Procedure......................................................................................................................11984
Flushing The Power Steering System......................................................................................................11984
Steering Wheel Free Play Adjustment.....................................................................................................11984
Front End Alignment Inspection and Adjustment...........................................................................................11985
Main Data and Specifications............................................................................................................11990
Special Tools...........................................................................................................................11991
Power Steering Gear.....................................................................................................................11992
Power Steering Gear and Associated Parts............................................................................................11992
Removal.............................................................................................................................11992
Installation........................................................................................................................11993
Steering Gear Disassembled View.....................................................................................................11994
Disassembly.........................................................................................................................11994
Inspection and Repair...............................................................................................................11996
Reassembly..........................................................................................................................11997
Main Data and Specifications........................................................................................................11999
Special Tools.......................................................................................................................12000
Power Steering Pump.....................................................................................................................12001
Power Steering Pump and Associated Parts............................................................................................12001
Removal.............................................................................................................................12001
Installation........................................................................................................................12002
Power Steering Pump Disassembled View...............................................................................................12003
Disassembly.........................................................................................................................12003
Inspection and Repair...............................................................................................................12004
Reassembly..........................................................................................................................12005
Main Data and Specifications........................................................................................................12006
Center Track Rod Assembly...............................................................................................................12007
Center Track Rod Assembly and Associated Parts......................................................................................12007
Removal.............................................................................................................................12007
Inspection and Repair...............................................................................................................12008
Installation........................................................................................................................12008
Outer Track Rod Assembly................................................................................................................12009
Outer Track Rod Assembly and Associated Parts.......................................................................................12009
Removal.............................................................................................................................12009
Inspection and Repair...............................................................................................................12011
Installation........................................................................................................................12011
Relay Lever.............................................................................................................................12012
Relay Lever and Associated Parts....................................................................................................12012
Removal.............................................................................................................................12012
Installation........................................................................................................................12013
Steering Linkage and Associated Parts...................................................................................................12014
Main Data and Specifications........................................................................................................12014
Special Tools.......................................................................................................................12015
Supplemental Restraint System Steering Wheel & Column...................................................................................12016
Service Precaution..................................................................................................................12016
SRS Connectors (3 pin)..............................................................................................................12016
SRS Connectors (2 pin)..............................................................................................................12016
Inflator Module.........................................................................................................................12018
Inflator Module and Associated Parts................................................................................................12018
Removal.............................................................................................................................12018
Inspection and Repair...............................................................................................................12019
Installation........................................................................................................................12019
Steering Wheel..........................................................................................................................12020
Steering Wheel and Associated Parts.................................................................................................12020
Removal.............................................................................................................................12020
Installation........................................................................................................................12022
Combination Switch......................................................................................................................12023
Combination Switch and Associated Parts.............................................................................................12023
Removal.............................................................................................................................12023
Installation........................................................................................................................12025
Lock Cylinder...........................................................................................................................12027
Lock Cylinder and Associated Parts..................................................................................................12027
Removal.............................................................................................................................12027
Installation........................................................................................................................12029
System Inspection...................................................................................................................12030
Steering Column.........................................................................................................................12031
Steering Column and Associated Parts................................................................................................12031
Removal.............................................................................................................................12031
Inspection..........................................................................................................................12033
Installation........................................................................................................................12035
System Inspection...................................................................................................................12036
Supplemental Restraint System Steering Wheel & Column and Associated Parts..............................................................12037
Main Data and Specifications........................................................................................................12037
Special Tools.......................................................................................................................12038
Sec.3 SUSPENSION..............................................................................................................................12083
3C FRONT SUSPENSION.......................................................................................................................12039
Service Precaution......................................................................................................................12039
General Description.....................................................................................................................12040
General Diagnosis.......................................................................................................................12041
Shock Absorber..........................................................................................................................12044
Shock Absorber and Associated Parts.................................................................................................12044
Removal.............................................................................................................................12044
Inspection and Repair...............................................................................................................12045
Installation........................................................................................................................12045
Stabilizer Bar..........................................................................................................................12046
Stabilizer Bar and Associated Parts.................................................................................................12046
Removal.............................................................................................................................12046
Inspection and Repair...............................................................................................................12046
Installation........................................................................................................................12046
Torsion Bar.............................................................................................................................12047
Torsion Bar and Associated Parts....................................................................................................12047
Removal.............................................................................................................................12047
Inspection and Repair...............................................................................................................12048
Installation........................................................................................................................12048
Special Tools...........................................................................................................................12065
3D REAR SUSPENSION........................................................................................................................12066
Service Precaution......................................................................................................................12066
General Description.....................................................................................................................12067
Coil Spring.............................................................................................................................12068
Coil Spring and Associated Parts....................................................................................................12068
Removal.............................................................................................................................12068
Inspection and Repair...............................................................................................................12069
Installation........................................................................................................................12069
Shock Absorber..........................................................................................................................12070
Shock Absorber and Associated Parts.................................................................................................12070
Removal.............................................................................................................................12070
Inspection and Repair...............................................................................................................12070
Installation........................................................................................................................12071
Trailing Link...........................................................................................................................12072
Trailing Link and Associated Parts..................................................................................................12072
Removal.............................................................................................................................12072
Inspection and Repair...............................................................................................................12072
Installation........................................................................................................................12073
Center Link.............................................................................................................................12074
Center Link and Associated Parts....................................................................................................12074
Removal.............................................................................................................................12074
Inspection and Repair...............................................................................................................12074
Installation........................................................................................................................12075
Lateral Rod.............................................................................................................................12076
Lateral Rod and Associated Parts....................................................................................................12076
Removal.............................................................................................................................12076
Inspection and Repair...............................................................................................................12076
Installation........................................................................................................................12077
Stabilizer Bar..........................................................................................................................12078
Stabilizer Bar and Associated Parts.................................................................................................12078
Removal.............................................................................................................................12078
Inspection and Repair...............................................................................................................12078
Installation........................................................................................................................12079
Main Data and Specifications............................................................................................................12080
Special Tools...........................................................................................................................12082
3E WHEEL AND TIRE SYSTEM..................................................................................................................12083
Service Precaution......................................................................................................................12083
General Description.....................................................................................................................12084
Diagnosis...............................................................................................................................12085
Wheel...................................................................................................................................12091
Wheel and Associated Parts..........................................................................................................12091
Removal.............................................................................................................................12091
Installation........................................................................................................................12091
Tire....................................................................................................................................12092
Tire Replacement....................................................................................................................12092
Temporary Spare Tire................................................................................................................12092
General Balance Procedure...........................................................................................................12092
Balancing Wheel and Tire............................................................................................................12093
Main Data and Specifications............................................................................................................12094
Sec.4 DRIVELINE/AXLE..........................................................................................................................12095
4A1 DIFFERENTIAL (FRONT)..................................................................................................................12095
Service Precaution......................................................................................................................12095
Front Drive Axle........................................................................................................................12096
Diagnosis...........................................................................................................................12096
Pinion Shaft Oil Seal...................................................................................................................12097
Pinion Shaft Oil Seal and Associated Parts..........................................................................................12097
Removal.............................................................................................................................12097
Inspection and Repair...............................................................................................................12098
Installation........................................................................................................................12098
Front Drive Axle Assembly...............................................................................................................12099
Front Drive Axle Assembly and Associated Parts......................................................................................12099
Removal.............................................................................................................................12099
Installation........................................................................................................................12100
Differential Assembly...................................................................................................................12102
Disassembled View...................................................................................................................12102
Disassembly.........................................................................................................................12103
Reassembly..........................................................................................................................12105
Differential Cage Assembly..............................................................................................................12114
Disassembled View...................................................................................................................12114
Disassembly.........................................................................................................................12114
Inspection and Repair...............................................................................................................12115
Reassembly..........................................................................................................................12116
Main Data and Specifications............................................................................................................12118
Special Tools...........................................................................................................................12120
4A2 DIFFERENTIAL (REAR)...................................................................................................................12122
Service Precaution......................................................................................................................12122
General Description.....................................................................................................................12123
Diagnosis...............................................................................................................................12124
Axle Housing............................................................................................................................12125
Axle Housing and Associated Parts...................................................................................................12125
Removal.............................................................................................................................12125
Oil Seal Replacement................................................................................................................12126
Installation........................................................................................................................12126
Pinion Oil Seal.........................................................................................................................12127
Pinion Oil Seal and Associated Parts................................................................................................12127
Removal.............................................................................................................................12127
Inspection and Repair...............................................................................................................12128
Installation........................................................................................................................12128
Differential Assembly...................................................................................................................12129
Differential Assembly and Associated Parts..........................................................................................12129
Removal.............................................................................................................................12129
Installation........................................................................................................................12130
Disassembled View...................................................................................................................12131
Disassembly.........................................................................................................................12132
Reassembly..........................................................................................................................12134
Limited Slip Differential...............................................................................................................12142
Disassembled View...................................................................................................................12142
Disassembly.........................................................................................................................12143
Inspection and Repair...............................................................................................................12143
Reassembly..........................................................................................................................12145
Main Data and Specifications............................................................................................................12148
Special Tools...........................................................................................................................12149
4B2 DRIVELINE CONTROL SYSTEM (TOD)........................................................................................................12151
Service Precaution......................................................................................................................12151
General Description.....................................................................................................................12152
System Components.......................................................................................................................12154
Parts Location......................................................................................................................12154
Functions of Indicator Lamp.............................................................................................................12158
Diagnosis...............................................................................................................................12162
Basic Diagnostic Flow Chart.............................................................................................................12165
Parts Location..........................................................................................................................12166
Circuit Diagram.........................................................................................................................12167
Connector List..........................................................................................................................12170
Checking Failed Pin.....................................................................................................................12171
Checking Failed TOD Control Unit Pin....................................................................................................12174
Tech 2 Scan Tool....................................................................................................................12175
Diagnostic Trouble Codes................................................................................................................12178
Diagnosis from Trouble Codes............................................................................................................12179
Trouble Diagnosis Depending on The Status of TOD Indicator..............................................................................12196
Diagnosis from Symptom..................................................................................................................12215
4C DRIVE SHAFT SYSTEM....................................................................................................................12223
Service Precaution......................................................................................................................12223
General Description.....................................................................................................................12223
Diagnosis...............................................................................................................................12224
Front Hub and Disc......................................................................................................................12225
Disassembled View...................................................................................................................12225
Disassembly.........................................................................................................................12225
Inspection and Repair...............................................................................................................12226
Reassembly..........................................................................................................................12227
Main Data and Specifications........................................................................................................12230
Special Tools.......................................................................................................................12231
Front Drive Shaft Joint.................................................................................................................12232
Front Drive Shaft Joints Replacement................................................................................................12232
Front Axle Drive Shaft..................................................................................................................12233
Front Axle Drive Shaft and Associated Parts.........................................................................................12233
Disassembly.........................................................................................................................12234
Inspection and Repair...............................................................................................................12235
Bushing Replacement.................................................................................................................12235
Reassembly..........................................................................................................................12236
Front Propeller Shaft...................................................................................................................12238
General Description.................................................................................................................12238
Front Propeller Shaft and Associated Parts..........................................................................................12238
Removal.............................................................................................................................12239
Installation........................................................................................................................12239
Inspection and Repair...............................................................................................................12240
Main Data and Specifications........................................................................................................12242
Rear Propeller Shaft....................................................................................................................12243
General Description.................................................................................................................12243
Rear Propeller Shaft and Associated Parts...........................................................................................12243
Removal.............................................................................................................................12244
Installation........................................................................................................................12244
Disassembly.........................................................................................................................12245
Universal Joint Disassembly.........................................................................................................12246
Inspection and Repair...............................................................................................................12247
Universal Joint Reassembly..........................................................................................................12248
Reassembly..........................................................................................................................12249
Main Data and Specifications........................................................................................................12250
4D2 TRANSFER CASE (TOD)...................................................................................................................12251
Service Precaution......................................................................................................................12251
Transfer Case Assembly..................................................................................................................12252
Removal.............................................................................................................................12253
Installation........................................................................................................................12253
Transfer Rear Oil Seal..................................................................................................................12255
Transfer Rear Oil Seal and Associated Parts.........................................................................................12255
Removal.............................................................................................................................12255
Installation........................................................................................................................12255
TOD ECU.................................................................................................................................12257
Removal.............................................................................................................................12257
Installation........................................................................................................................12257
Unit Repair.............................................................................................................................12258
Inspection..........................................................................................................................12258
Transfer Case...........................................................................................................................12259
Disassembled View...................................................................................................................12259
Disassembly.........................................................................................................................12259
Reassembly..........................................................................................................................12260
Transfer Cover Assembly.................................................................................................................12262
Disassembled View...................................................................................................................12262
Disassembly.........................................................................................................................12262
Reassembly..........................................................................................................................12264
Transfer Case Assembly Clutch Pack and Clutch Cam.......................................................................................12266
Disassembled View...................................................................................................................12266
Disassembly.........................................................................................................................12266
Sprocket and Mechanical Lock............................................................................................................12268
Disassembled View...................................................................................................................12268
Disassembly.........................................................................................................................12268
Output Shafts and Shift Control Shaft...................................................................................................12270
Disassembled View...................................................................................................................12270
Disassembly.........................................................................................................................12271
Transfer Case...........................................................................................................................12273
Disassembled View...................................................................................................................12273
Disassembly.........................................................................................................................12274
Inspection and Repair...............................................................................................................12276
Transfer Case...........................................................................................................................12280
Disassembled View...................................................................................................................12280
Reassembly..........................................................................................................................12280
Output Shafts and Shift Control Shaft...................................................................................................12284
Disassembled View...................................................................................................................12284
Reassembly..........................................................................................................................12284
Sprocket and Mechanical Lock............................................................................................................12287
Disassembled View...................................................................................................................12287
Reassembly..........................................................................................................................12287
Clutch Pack and Clutch Cam..............................................................................................................12289
Disassembled View...................................................................................................................12289
Reassembly..........................................................................................................................12289
Main Data and Specifications............................................................................................................12291
Special Tools...........................................................................................................................12293
Sec.5 BRAKES..................................................................................................................................12402
5A BRAKE CONTROL SYSTEM...................................................................................................................12294
Service Precaution......................................................................................................................12295
General Description.....................................................................................................................12296
System Components...................................................................................................................12297
Electronic Hydraulic Control Unit (EHCU)............................................................................................12297
ABS Warning Light...................................................................................................................12297
Wheel Speed Sensor..................................................................................................................12297
G-Sensor............................................................................................................................12297
Normal and Anti-lock Braking........................................................................................................12297
Brake Pedal Travel..................................................................................................................12297
Acronyms and Abbreviations..........................................................................................................12297
General Diagnosis.......................................................................................................................12298
General Information.................................................................................................................12298
ABS Service Precautions.............................................................................................................12298
General Service Precautions.........................................................................................................12298
Note on Intermittents...............................................................................................................12298
Test Driving ABS Complaint Vehicles.................................................................................................12299
"ABS" Warning Light.................................................................................................................12299
Normal Operation....................................................................................................................12299
Basic Diagnostic Flow Chart.........................................................................................................12299
Basic Inspection Procedure..........................................................................................................12300
Tech 2 Scan Tool....................................................................................................................12301
Getting Started.....................................................................................................................12302
Operating Procedure.................................................................................................................12302
Data List...............................................................................................................................12304
EHCU Connector Pin-out Checks...........................................................................................................12305
Circuit Diagram.....................................................................................................................12306
Connector List......................................................................................................................12308
Part Location.......................................................................................................................12310
Symptom Diagnosis.......................................................................................................................12311
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate......................................................................12312
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................12313
Chart A-2 Uneven Braking Occurs While ABS Works.....................................................................................12313
Chart A-3, TA-3 The Wheels Are Locked...............................................................................................12314
Chart A-4 Brake Pedal Feed Is Abnormal..............................................................................................12315
Chart A-5,TA-5 Braking Sound (From EHCU) Is Heard While Not Braking.................................................................12316
Diagnostic Trouble Codes................................................................................................................12317
Diagnosis By "ABS" Warning Light Illumination Pattern...................................................................................12318
Diagnostic Trouble Codes (DTCs).....................................................................................................12319
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................12322
Chart B-2 EHCU Abnormality (DTC 14).................................................................................................12322
Chart B-3 Power Voltage Drop (DTC 15)...............................................................................................12323
Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)...........................................................................12323
Chart B-5 G-Sensor Circuit (DTC 21).................................................................................................12324
Chart B-6 Abnormal Transmission Input (DTC 23)......................................................................................12325
Chart B-7 Transfer Monitor (DTC 24).................................................................................................12325
Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32)..........................................................................12326
Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35)..........................................................................12326
Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41).........................................................................12326
Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42)..............................................................................12327
Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43).........................................................................12327
Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44)..............................................................................12327
Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45).......................................................................12328
Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)............................................................................12328
Chart B-16 FL Speed Sensor Disconnection (DTC 51)...................................................................................12328
Chart B-17 FR Speed Sensor Disconnection (DTC 52)...................................................................................12329
Chart B-18 RL Speed Sensor Disconnection (DTC 53)...................................................................................12329
Chart B-19 RR Speed Sensor Disconnection (DTC 54)...................................................................................12330
Chart B-20 FL Speed Sensor Short Circuit (DTC 61)...................................................................................12331
Chart B-21 FR Speed Sensor Short Circuit (DTC 62)...................................................................................12332
Chart B-22 RL Speed Sensor Short Circuit (DTC 63)...................................................................................12333
Chart B-23 RR Speed Sensor Short Circuit (DTC 64)...................................................................................12334
Chart B-24 Sensor Signal Input Abnormality (DTC 65).................................................................................12335
Sensor Signal Abnormality Criteria using TECH 2.....................................................................................12335
Unit Inspection Procedure...............................................................................................................12336
Chart C-1-1 FL Sensor Output Inspection Procedure...................................................................................12336
Chart C-1-2 FR Sensor Output Inspection Procedure...................................................................................12337
Chart C-1-3 RL Sensor Output Inspection Procedure...................................................................................12337
Chart C-1-4 RR Sensor Output Inspection Procedure...................................................................................12338
Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)..........................................................................12338
Chart C-2 Transmission Input Inspection Procedure...................................................................................12339
Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2).....................................................................12339
Special Tools...........................................................................................................................12340
5B ANTI-LOCK BRAKE SYSTEM.................................................................................................................12341
Service Precaution......................................................................................................................12341
Electronic Hydraulic Control Unit.......................................................................................................12342
Electronic Hydraulic Control Unit and Associated Parts..............................................................................12342
Removal.............................................................................................................................12342
Installation........................................................................................................................12342
G-Sensor................................................................................................................................12343
Removal.............................................................................................................................12343
Inspection and Repair...............................................................................................................12343
Installation........................................................................................................................12343
Front Wheel Speed Sensor................................................................................................................12344
Front Wheel Speed Sensor and Associated Parts.......................................................................................12344
Removal.............................................................................................................................12344
Inspection and Repair...............................................................................................................12345
Installation........................................................................................................................12345
Rear Wheel Speed Sensor.................................................................................................................12346
Rear Wheel Speed Sensor and Associated Parts........................................................................................12346
Removal.............................................................................................................................12346
Inspection and Repair...............................................................................................................12346
Installation........................................................................................................................12346
5C POWER-ASSISTED BRAKE SYSTEM............................................................................................................12347
Service Precaution......................................................................................................................12348
General Description.....................................................................................................................12348
Diagnosis...............................................................................................................................12351
General Diagnosis.......................................................................................................................12352
Hydraulic Brakes........................................................................................................................12355
Filling Master Cylinder Reservoir...................................................................................................12355
Deterioration of Brake Fluid........................................................................................................12355
Leakage of Brake Fluid..............................................................................................................12355
Bleeding Brake Hydraulic System.....................................................................................................12355
Flushing Brake Hydraulic System.....................................................................................................12356
Brake Pipes and Hoses...............................................................................................................12356
Brake Hose Inspection...............................................................................................................12356
Front / Rear Caliper Brake Hose.........................................................................................................12357
Front / Rear Caliper Brake Hose and Associated Parts................................................................................12357
Removal.............................................................................................................................12357
Installation........................................................................................................................12357
Rear Axle Brake Hose....................................................................................................................12358
Rear Axle Brake Hose and Associated Parts...........................................................................................12358
Removal.............................................................................................................................12358
Installation........................................................................................................................12358
Brake Pipe..............................................................................................................................12359
Removal.............................................................................................................................12359
Installation........................................................................................................................12359
P & B (Proportioning and Bypass) Valve..................................................................................................12360
P & B (Proportioning and Bypass) Valve Sectional View...............................................................................12360
Removal.............................................................................................................................12360
Installation........................................................................................................................12360
Main Data and Specifications........................................................................................................12361
Brake Pedal.............................................................................................................................12362
Checking Pedal Height...............................................................................................................12362
Checking Pedal Travel...............................................................................................................12362
Brake Pedal and Associated Parts....................................................................................................12363
Removal.............................................................................................................................12363
Installation........................................................................................................................12363
Stoplight Switch........................................................................................................................12364
Removal.............................................................................................................................12364
Installation........................................................................................................................12364
Main Data and Specifications........................................................................................................12365
Fluid Reservoir Tank....................................................................................................................12366
Fluid Reservoir Tank and Associated Parts...........................................................................................12366
Removal.............................................................................................................................12366
Installation........................................................................................................................12366
Master Cylinder Assembly................................................................................................................12367
Master Cylinder Assembly and Associated Parts.......................................................................................12367
Removal.............................................................................................................................12367
Inspection and Repair...............................................................................................................12367
Installation........................................................................................................................12368
Main Data and Specifications........................................................................................................12369
Special Tools.......................................................................................................................12370
Vacuum Booster Assembly.................................................................................................................12371
Vacuum Booster Assembly and Associated Parts........................................................................................12371
Removal.............................................................................................................................12371
Inspection and Repair...............................................................................................................12371
Installation........................................................................................................................12372
Exterior Components.....................................................................................................................12374
Exterior Components and Associated Parts............................................................................................12374
Removal.............................................................................................................................12374
Inspection and Repair...............................................................................................................12375
Installation........................................................................................................................12375
Vacuum Booster Overhaul.................................................................................................................12375
Vacuum Booster......................................................................................................................12375
Main Data and Specifications........................................................................................................12376
Special Tools.......................................................................................................................12377
Front Disc Brake Pads...................................................................................................................12378
Front Disc Brake Pads Inspection....................................................................................................12378
Front Disc Brake Pads and Associated Parts..........................................................................................12378
Removal.............................................................................................................................12379
Installation........................................................................................................................12379
Front Disc Brake Rotor..................................................................................................................12381
Inspection..........................................................................................................................12381
Replacing Brake Rotors..............................................................................................................12381
Front Disc Brake Caliper Assembly.......................................................................................................12383
Front Disc Brake Caliper Assembly and Associated Parts..............................................................................12383
Removal.............................................................................................................................12383
Installation........................................................................................................................12384
Front Disc Brake Caliper................................................................................................................12386
Front Disc Brake Caliper Disassembled View..........................................................................................12386
Disassembly.........................................................................................................................12386
Inspection and Repair...............................................................................................................12387
Reassembly..........................................................................................................................12387
Main Data and Specifications........................................................................................................12389
Rear Disc Brake Pads....................................................................................................................12390
Brake Pads Inspection...............................................................................................................12390
Brake Pads and Associated Parts.....................................................................................................12390
Removal.............................................................................................................................12391
Installation........................................................................................................................12391
Rear Disc Brake Rotor...................................................................................................................12393
Inspection..........................................................................................................................12393
Replacing Brake Rotors..............................................................................................................12393
Refinishing Brake Rotors............................................................................................................12393
Rear Drum (In Disc) Inside Diameter Check...........................................................................................12394
Rear Disc Brake Caliper Assembly........................................................................................................12395
Rear Disc Brake Caliper Assembly and Associated Parts...............................................................................12395
Removal.............................................................................................................................12395
Installation........................................................................................................................12396
Rear Disc Brake Caliper.................................................................................................................12398
Rear Disc Brake Caliper Disassembled View...........................................................................................12398
Disassembly.........................................................................................................................12398
Inspection and Repair...............................................................................................................12399
Reassembly..........................................................................................................................12399
Main Data and Specifications........................................................................................................12401
5D PARKING BRAKE SYSTEM...................................................................................................................12402
Service Precaution......................................................................................................................12402
General Description.....................................................................................................................12402
Operation...............................................................................................................................12403
Parking Brake Lever and Front Cable.....................................................................................................12404
Parking Brake Lever, Front Cable and Associated Parts...............................................................................12404
Removal.............................................................................................................................12404
Installation........................................................................................................................12405
Parking Brake Rear Cable................................................................................................................12406
Parking Brake Rear Cable and Associated Parts.......................................................................................12406
Removal.............................................................................................................................12406
Installation........................................................................................................................12407
Inspection and Repair...............................................................................................................12408
Parking Brake Adjustment............................................................................................................12408
Main Data and Specifications............................................................................................................12409
Sec.6 ENGINE..................................................................................................................................13101
6A ENGINE MECHANICAL......................................................................................................................12410
Service Precaution......................................................................................................................12411
General Description.....................................................................................................................12412
Engine Diagnosis........................................................................................................................12413
Cylinder Head Cover LH..................................................................................................................12427
Removal.............................................................................................................................12427
Installation........................................................................................................................12428
Cylinder Head Cover RH..................................................................................................................12430
Removal.............................................................................................................................12430
Installation........................................................................................................................12431
Common Chamber..........................................................................................................................12433
Removal.............................................................................................................................12433
Installation........................................................................................................................12433
Exhaust Manifold LH.....................................................................................................................12435
Removal.............................................................................................................................12435
Installation........................................................................................................................12435
Exhaust Manifold RH.....................................................................................................................12437
Removal.............................................................................................................................12437
Installation........................................................................................................................12438
Crankshaft Pulley.......................................................................................................................12439
Removal.............................................................................................................................12439
Installation........................................................................................................................12439
Timing Belt.............................................................................................................................12440
Removal.............................................................................................................................12440
Installation........................................................................................................................12441
Camshaft................................................................................................................................12444
Removal.............................................................................................................................12444
Installation........................................................................................................................12444
Cylinder Head...........................................................................................................................12447
Removal.............................................................................................................................12447
Installation........................................................................................................................12447
Valve Stem Oil Controller , Valve Spring and Valve Guide................................................................................12449
Removal.............................................................................................................................12449
Installation........................................................................................................................12449
Piston, Piston Ring and Connecting Rod..................................................................................................12450
Removal.............................................................................................................................12450
Installation........................................................................................................................12451
Crankshaft and Main Bearings............................................................................................................12452
Removal.............................................................................................................................12452
Installation........................................................................................................................12453
Rear Oil Seal...........................................................................................................................12457
Removal.............................................................................................................................12457
Installation........................................................................................................................12457
Engine Assembly.........................................................................................................................12458
Removal.............................................................................................................................12458
Installation........................................................................................................................12458
Cylinder Head...........................................................................................................................12461
Cylinder Head and Associated Parts..................................................................................................12461
Disassembly.........................................................................................................................12461
Clean...............................................................................................................................12462
Inspection and Repair...............................................................................................................12462
Reassembly..........................................................................................................................12462
Valve Spring, Oil Controller, Valve, Valve Guide........................................................................................12465
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts...............................................................12465
Disassembly.........................................................................................................................12465
Inspection and Repair...............................................................................................................12466
Reassembly..........................................................................................................................12469
Valve Clearance Adjustments.........................................................................................................12470
Camshaft................................................................................................................................12472
Camshaft and Associated Parts.......................................................................................................12472
Disassembly.........................................................................................................................12472
Inspection and Repair...............................................................................................................12473
Reassembly..........................................................................................................................12475
Crankshaft..............................................................................................................................12478
Crankshaft and Associated Parts.....................................................................................................12478
Disassembly.........................................................................................................................12478
Inspection and Repair...............................................................................................................12479
Inspection and Repair...............................................................................................................12480
Reassembly..........................................................................................................................12482
Piston and Connecting Rod...............................................................................................................12486
Piston, Connecting Rod and Associate Parts..........................................................................................12486
Disassembly.........................................................................................................................12486
Inspection and Repair...............................................................................................................12487
Reassembly..........................................................................................................................12491
Cylinder Block..........................................................................................................................12494
Cylinder Block and Associated Parts.................................................................................................12494
Disassembly.........................................................................................................................12494
Inspection and Repair...............................................................................................................12495
Reassembly..........................................................................................................................12496
Main Data and Specification.............................................................................................................12499
Special Tool............................................................................................................................12505
6B ENGINE COOLING.........................................................................................................................12507
Service Precaution......................................................................................................................12507
General Description.....................................................................................................................12508
Diagnosis...............................................................................................................................12511
Draining and Refilling Cooling System...................................................................................................12512
Engine coolant change...................................................................................................................12512
Water Pump..............................................................................................................................12513
Water Pump and Associated Parts.....................................................................................................12513
Removal.............................................................................................................................12513
Inspection..........................................................................................................................12513
Installation........................................................................................................................12513
Thermostat..............................................................................................................................12514
Thermostat and Associated Parts.....................................................................................................12514
Removal.............................................................................................................................12514
Inspection..........................................................................................................................12514
Installation........................................................................................................................12514
Radiator................................................................................................................................12515
Radiator and Associated Parts.......................................................................................................12515
Removal.............................................................................................................................12515
Inspection..........................................................................................................................12516
Installation........................................................................................................................12517
Drive Belt and Cooling Fan..............................................................................................................12518
Drive Belt and Associated Parts.....................................................................................................12518
Inspection..........................................................................................................................12518
Installation........................................................................................................................12518
Main Data and Specifications............................................................................................................12519
Special Tool............................................................................................................................12520
6C ENGINE FUEL............................................................................................................................12521
Service Precaution......................................................................................................................12521
General Description.....................................................................................................................12522
Fuel Metering...........................................................................................................................12523
Fuel Filter.............................................................................................................................12524
Fuel Filter and Associated Parts....................................................................................................12524
Removal.............................................................................................................................12524
Inspection..........................................................................................................................12524
Installation........................................................................................................................12524
Inspection..........................................................................................................................12525
In-Tank Fuel Filter.................................................................................................................12525
Fuel Pump Flow Test.................................................................................................................12525
Fuel Pump...............................................................................................................................12526
Fuel Pump and Associated Parts......................................................................................................12526
Removal.............................................................................................................................12526
Installation........................................................................................................................12526
Fuel Pump Relay.........................................................................................................................12527
General Description.................................................................................................................12527
Fuel Tank...............................................................................................................................12527
Fuel Tank and Associated Parts......................................................................................................12527
Removal.............................................................................................................................12528
Installation........................................................................................................................12528
Fuel Tube / Quick-Connect Fittings......................................................................................................12528
Precautions.........................................................................................................................12528
Cautions During Work................................................................................................................12528
Removal.............................................................................................................................12528
Reuse of Quick-Connector............................................................................................................12530
Assembling Advice...................................................................................................................12530
Fuel Gauge Unit.........................................................................................................................12531
Fuel Gauge Unit and Associated Parts................................................................................................12531
Removal.............................................................................................................................12531
Installation........................................................................................................................12531
Fuel Filler Cap.........................................................................................................................12532
General Description.................................................................................................................12532
Inspection..........................................................................................................................12532
Main Data and Specifications............................................................................................................12532
6D1 ENGINE ELECTRICAL......................................................................................................................12533
Battery.................................................................................................................................12533
General Description.....................................................................................................................12533
Diagnosis...............................................................................................................................12533
Battery Charging....................................................................................................................12534
Jump Starting.......................................................................................................................12534
Battery Removal.....................................................................................................................12535
Battery Installation................................................................................................................12535
Main Data and Specifications............................................................................................................12536
6D2 IGNITION SYSTEM........................................................................................................................12537
Service Precaution......................................................................................................................12537
General Description.....................................................................................................................12538
Diagnosis...............................................................................................................................12541
Ignition Coil...........................................................................................................................12541
Removal.............................................................................................................................12541
Inspection and Repair...............................................................................................................12541
Installation........................................................................................................................12541
Spark Plug..............................................................................................................................12542
Removal.............................................................................................................................12542
Inspection and Repair...............................................................................................................12542
Installation........................................................................................................................12542
Crankshaft Position Sensor..............................................................................................................12543
Removal.............................................................................................................................12543
Installation........................................................................................................................12543
Main Data and Specifications............................................................................................................12544
6D3 STARTING AND CHARGING SYSTEM...........................................................................................................12545
Service Precaution......................................................................................................................12545
Starting System.........................................................................................................................12546
General Description.....................................................................................................................12546
Diagnosis...............................................................................................................................12548
Starter.................................................................................................................................12549
Removal.............................................................................................................................12549
Installation........................................................................................................................12549
Disassembled View...................................................................................................................12550
Disassembly.........................................................................................................................12551
Inspection and Repair...............................................................................................................12553
Reassembly..........................................................................................................................12557
Main Data and Specifications........................................................................................................12559
Charging System.........................................................................................................................12562
General Description.....................................................................................................................12562
General On-Vehicle Inspection...........................................................................................................12562
Generator...............................................................................................................................12563
Removal.............................................................................................................................12563
Inspection..........................................................................................................................12563
Installation........................................................................................................................12563
Disassembled View...................................................................................................................12564
Disassembly.........................................................................................................................12565
Inspection and Repair...............................................................................................................12567
Reassembly..........................................................................................................................12569
Bench Test..........................................................................................................................12569
Main Data and Specifications............................................................................................................12570
6E 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS............................................................................................12571
Specifications..........................................................................................................................12575
Tightening Specifications...........................................................................................................12575
Diagrams and Schematics.................................................................................................................12576
PCM Wiring Diagram (1 of 8).........................................................................................................12576
PCM Wiring Diagram (2 of 8).........................................................................................................12577
PCM Wiring Diagram (3 of 8).........................................................................................................12578
PCM Wiring Diagram (4 of 8).........................................................................................................12579
PCM Wiring Diagram (5 of 8).........................................................................................................12580
PCM Wiring Diagram (6 of 8).........................................................................................................12581
PCM Wiring Diagram (7 of 8).........................................................................................................12582
PCM Wiring Diagram (8 of 8).........................................................................................................12583
PCM Pinouts.............................................................................................................................12584
PCM Pinout Table, 32-Way Red Connector-Row "A"......................................................................................12584
PCM Pinout Table, 32-Way Red Connector-Row "B"......................................................................................12586
PCM Pinout Table, 32-Way White Connector-Row "C"....................................................................................12587
PCM Pinout Table, 32-Way White Connector-Row "D"....................................................................................12588
PCM Pinout Table, 32-Way Blue Connector-Row "E".....................................................................................12590
PCM Pinout Table, 32-Way Blue Connector-Row "F".....................................................................................12591
Component Locators......................................................................................................................12592
Engine Component Locator............................................................................................................12592
Engine Component Locator Table......................................................................................................12592
Undercarriage Component Locator.....................................................................................................12593
Undercarriage Component Locator Table...............................................................................................12593
Fuse and Relay Panel (Underhood Electrical Center)..................................................................................12594
Sensors and Miscellaneous Component Locators........................................................................................12595
Diagnosis...............................................................................................................................12597
Strategy-Based Diagnostics..........................................................................................................12597
DTC Stored..........................................................................................................................12597
No DTC..............................................................................................................................12597
No Matching Symptom.................................................................................................................12597
Intermittents.......................................................................................................................12597
No Trouble Found....................................................................................................................12597
Verifying Vehicle Repair............................................................................................................12597
General Service Information.............................................................................................................12597
OBD II Serviceablity Issues.........................................................................................................12597
Emissions Control Information Label.................................................................................................12598
Maintenance Schedule................................................................................................................12598
Visual / Physical Engine Compartment Inspection.....................................................................................12598
Basic Knowledge of Tools Required...................................................................................................12599
Serial Data Communications..............................................................................................................12599
Class II Serial Data Communications.................................................................................................12599
On-Board Diagnostic (OBD) II............................................................................................................12599
On-Board Diagnostic Tests...........................................................................................................12599
Comprehensive Component Monitor Diagnostic Operation................................................................................12599
System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...................................12600
Common OBD II Terms.................................................................................................................12600
The Diagnostic Executive............................................................................................................12600
DTC Types...........................................................................................................................12601
Decimal/Binary/Hexadecimal Conversions..............................................................................................12603
Verifying Vehicle Repair............................................................................................................12603
Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool.........................................................................12603
Tech 2..............................................................................................................................12604
Tech 2 Features.....................................................................................................................12604
Getting Started.....................................................................................................................12605
Operating Procedure (For Example)...................................................................................................12605
DTC Modes...........................................................................................................................12606
DTC Information Mode................................................................................................................12607
Miscellaneous Test..................................................................................................................12607
Lamps Test..........................................................................................................................12608
Relays Test.........................................................................................................................12609
EVAP Test...........................................................................................................................12610
Idle Air Control (IAC) System Test..................................................................................................12611
Fuel System Test....................................................................................................................12613
EGR Control Test....................................................................................................................12614
Variable Intake Manifold Solenoid Test..............................................................................................12615
Injector Balance Test...............................................................................................................12616
Plotting Snapshot Graph.................................................................................................................12617
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)......................................................12618
Flow Chart for Snapshot Replay (Plotting Graph).....................................................................................12619
Primary System-Based Diagnostic.........................................................................................................12620
Fuel Control Heated Oxygen Sensor...................................................................................................12620
HO2S Heater.........................................................................................................................12620
Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation.....................................................................12620
Misfire Monitor Diagnostic Operation....................................................................................................12621
Misfire Counters....................................................................................................................12621
Fuel Trim System Monitor Diagnostic Operation...........................................................................................12622
Fuel Trim Cell Diagnostic Weights...................................................................................................12622
On-Board Diagnostic (OBD II) System Check...............................................................................................12623
A/C Clutch Control Circuit Diagnosis....................................................................................................12626
Electronic Ignition System Diagnosis....................................................................................................12632
Visual Check of The Evaporative Emission Canister.......................................................................................12632
Fuel Metering System Check..............................................................................................................12632
Idle Air Control (IAC) Valve............................................................................................................12632
Fuel System Pressure Test...............................................................................................................12632
Fuel Injector Coil Test Procedure Fuel Injector Balance Test Procedure..................................................................12632
Knock Sensor Diagnosis..................................................................................................................12637
Powertrain Control Module (PCM) Diagnosis...............................................................................................12637
Multiple PCM Information Sensor DTCS Set................................................................................................12637
Exhaust Gas Recirculation (EGR) Diagnosis...............................................................................................12640
Engine Tech 2 Data Definitions and Ranges...............................................................................................12640
Typical Scan Data Values................................................................................................................12643
No Malfunction Indicator Lamp (MIL).....................................................................................................12649
Malfunction Indicator Lamp (MIL) "ON" Steady............................................................................................12652
Engine Cranks But Will Not Run..........................................................................................................12654
Fuel System Electrical Test.............................................................................................................12660
Fuel System Diagnosis...................................................................................................................12663
Idle Air Control (IAC) System Check.....................................................................................................12668
Knock Sensor (KS) System Check (Engine Knock, Poor Performance, or Poor Economy)........................................................12671
Exhaust Gas Recirculation (EGR) System Check............................................................................................12673
Manifold Absolute Pressure (MAP) Output Check...........................................................................................12675
Evaporative (EVAP) Emissions Canister Purge Valve Check.................................................................................12677
PCM Diagnostic Trouble Codes............................................................................................................12680
Diagnostic Trouble Code (DTC) P0101 MAF System Performance..............................................................................12684
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency....................................................................12687
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency...................................................................12690
Diagnostic Trouble Code (DTC) P0106 MAP System Performance..............................................................................12693
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage......................................................................12696
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage.....................................................................12699
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage......................................................................12702
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage.....................................................................12705
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage......................................................................12708
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage.....................................................................12711
Diagnostic Trouble Code (DTC) P0121 TP System Performance...............................................................................12714
Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage.......................................................................12717
Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage......................................................................12720
Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control......................................................12723
Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1............................................................12726
Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1...........................................................12729
Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1..................................................................12732
Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1..................................................12736
Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1.................................................................12739
Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2............................................................12742
Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2...........................................................12745
Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2...................................................12748
Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2.................................................................12751
Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1............................................................12754
Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1...........................................................12757
Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1..................................................................12760
Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1..................................................12764
Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Bank 2 Sensor 1.................................................................12767
Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2............................................................12770
Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2...........................................................12773
Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2..................................................12776
Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2.................................................................12779
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1........................................................................12782
Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1........................................................................12786
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2........................................................................12790
Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2........................................................................12794
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit..........................................................................12798
Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit..........................................................................12801
Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit..........................................................................12804
Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit..........................................................................12807
Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit..........................................................................12810
Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit..........................................................................12813
Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected.............................................................................12816
Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected...........................................................................12820
Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected...........................................................................12822
Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected...........................................................................12824
Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected...........................................................................12826
Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected...........................................................................12828
Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected...........................................................................12830
Diagnostic Trouble Code (DTC) P0325 KS Module Circuit...................................................................................12832
Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit...................................................................................12834
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit........................................................................12837
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency....................................................................12840
Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performance......................................................................12843
Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low..............................................................................12847
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit..........................................................................12851
Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit..........................................................................12854
Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit..........................................................................12857
Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit..........................................................................12860
Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit..........................................................................12863
Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit..........................................................................12866
Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient...............................................................................12869
Diagnostic Trouble Code (DTC) P0402 EGR Pintle Position Error...........................................................................12872
Diagnostic Trouble Code (DTC) P0404 EGR Pintle Open/Stuck...............................................................................12874
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage.....................................................................................12876
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage....................................................................................12879
Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1....................................................................12882
Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2....................................................................12885
Diagnostic Trouble Code (DTC) P0440 EVAP System.........................................................................................12887
Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected.....................................................................12891
Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Blocked..........................................................................12894
Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor Low Voltage...............................................................12897
Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor High Voltage..............................................................12900
Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit豊ow Voltage................................................................12903
Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit蓬igh Voktage...............................................................12905
Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input...............................................................................12907
Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM.....................................................................12910
Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM....................................................................12913
Diagnostic Trouble Code (DTC) P0562 System Voltage Low..................................................................................12916
Diagnostic Trouble Code (DTC) P0563 System Voltage High.................................................................................12918
Diagnostic Trouble Code (DTC) P0601 PCM Memory..........................................................................................12920
Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage........................................................12921
Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage................................................................12923
Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage........................................................12925
Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage.........................................................12928
Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage.........................................................12930
Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage........................................................12932
Diagnostic Trouble Code (DTC) P1121 TP Sensor Circuit Intermittent High Voltage.........................................................12935
Diagnostic Trouble Code (DTC) P1122 TP Sensor Circuit Intermittent Low Voltage..........................................................12937
Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1.........................................................12939
Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1..........................................................12943
Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1.........................................................12947
Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1..................................................12951
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration................................................................12955
Diagnostic Trouble Code (DTC) P1380 ABS Rough Road ABS System Fault.....................................................................12958
Diagnostic Trouble Code (DTC) P1381 ABS Rough Road Class 2 Serial Link Error............................................................12960
Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed....................................................................................12961
Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge...................................................................12964
Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM..................................................................................12967
Diagnostic Trouble Code (DTC) P1509 IAC System High RPM.................................................................................12970
Diagnostic Trouble Code (DTC) P1618 Serial Peripheral Interface (SPI) PCM Interprocessor Communication Error............................12973
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset................................................................................12974
Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM).................................................................12975
Diagnostic Trouble Code (DTC) P1650 Quad Driver Module "A" Fault........................................................................12978
Symptom Diagnosis.......................................................................................................................12981
Default Matrix Table....................................................................................................................13008
On-Vehicle ServiceCamshaft Position (CMP) Sensor........................................................................................13011
Crankshaft Position (CKP) Sensor........................................................................................................13011
Engine Coolant Temperature (ECT) Sensor.................................................................................................13012
Heated Oxygen Sensor (HO2S).............................................................................................................13013
Intake Air Temperature (IAT) Sensor.....................................................................................................13015
Knock Sensor (KS).......................................................................................................................13016
Mass Air Flow (MAF) Sensor..............................................................................................................13017
Manifold Absolute Pressure (MAP) Sensor.................................................................................................13018
Malfunction Indicator Lamp (MIL)........................................................................................................13019
Powertrain Control Module (PCM).........................................................................................................13019
EEPROM..................................................................................................................................13020
Throttle Position (TP) Sensor...........................................................................................................13020
Vehicle Speed Sensor (VSS)..............................................................................................................13021
Air Cleaner/Air Filter..................................................................................................................13022
Idle Air Control (IAC) Valve............................................................................................................13023
Common Chamber..........................................................................................................................13024
Accelerator Cable Assembly..............................................................................................................13024
Accelerator Pedal Replacement...........................................................................................................13027
Fuel Filter Cap.........................................................................................................................13029
Fuel Filter.............................................................................................................................13029
Fuel Gauge Unit.........................................................................................................................13031
Fuel Injectors..........................................................................................................................13032
Fuel Pressure Regulator.................................................................................................................13034
Fuel Metering System....................................................................................................................13036
Fuel Pump Assembly......................................................................................................................13036
Fuel Pump Relay.........................................................................................................................13037
Fuel Rail Assembly......................................................................................................................13037
Fuel Tank...............................................................................................................................13038
Throttle Body (TB)......................................................................................................................13040
Electronic Ignition System..............................................................................................................13042
Catalytic Converter.....................................................................................................................13043
Air Conditioning Relay..................................................................................................................13043
EVAP Canister Hoses.....................................................................................................................13044
EVAP Canister...........................................................................................................................13044
EVAP Canister Vent Solenoid.............................................................................................................13045
Fuel Tank Pressure Sensor...............................................................................................................13046
EVAP Canister Purge Solenoid............................................................................................................13046
Fuel Tank Vent Valve....................................................................................................................13047
Linear Exhaust Gas Recirculation (EGR) Valve............................................................................................13047
Positive Crankcase Ventilation (PCV) Valve..............................................................................................13048
Wiring and Connectors...................................................................................................................13049
PCM Connectors and Terminals............................................................................................................13049
Wire Harness Repair: Twisted Shielded Cable.............................................................................................13049
Twisted Leads...........................................................................................................................13050
Weather-Pack Connector..................................................................................................................13052
Com-Pack III............................................................................................................................13053
Metri-Pack..............................................................................................................................13053
General Description (PCM and Sensors)...................................................................................................13054
Catalyst Monitor Heated Oxygen Sensors..................................................................................................13055
58X Reference PCM Input.............................................................................................................13054
A/C Request Signal..................................................................................................................13054
Crankshaft Position (CKP) Sensor....................................................................................................13054
Camshaft Position (CMP) Sensor and Signal...........................................................................................13054
Engine Coolant Temperature (ECT) Sensor.............................................................................................13054
Electrically Erasable Programmable Read Only Memory (EEPROM)........................................................................13055
Fuel Control Heated Oxygen Sensors..................................................................................................13055
Intake Air Temperature (IAT) Sensor.................................................................................................13056
Knock Sensor........................................................................................................................13056
Linear Exhaust Gas Recirculation (EGR) Control......................................................................................13057
Mass Air Flow (MAF) Sensor..........................................................................................................13057
Manifold Absolute Pressure (MAP) Sensor.............................................................................................13057
Manifold Absolute Pressure (MAP) Sensor.............................................................................................13057
Powertrain Control Module (PCM).....................................................................................................13058
PCM Function........................................................................................................................13058
PCM Components......................................................................................................................13058
PCM Voltage Description.............................................................................................................13058
PCM Input/Outputs...................................................................................................................13058
PCM Service Precautions.............................................................................................................13059
Reprogramming The PCM...............................................................................................................13059
Throttle Position (TP) Sensor.......................................................................................................13059
Transmission Fluid Temperature (TFT) Sensor.........................................................................................13059
Transmission Range Switch...........................................................................................................13059
Vehicle Speed Sensor (VSS)..........................................................................................................13060
Use of Circuit Testing Tools........................................................................................................13060
Aftermarket Electrical and Vacuum Equipment.........................................................................................13060
Electrostatic Discharge Damage......................................................................................................13060
General Description (Air Induction).....................................................................................................13061
Air Induction System................................................................................................................13061
General Description (Fuel Metering).....................................................................................................13061
Acceleration Mode...................................................................................................................13061
Accelerator Controls................................................................................................................13061
Battery Voltage Correction Mode.....................................................................................................13061
CMP Signal..........................................................................................................................13061
Clear Flood Mode....................................................................................................................13061
Deceleration Mode...................................................................................................................13061
Engine Speed/Fuel Disable Mode......................................................................................................13061
Fuel Cutoff Mode....................................................................................................................13061
Fuel Injector.......................................................................................................................13061
Fuel Metering System Components.....................................................................................................13062
Fuel Metering System Purpose........................................................................................................13062
Fuel Pressure Regulator.............................................................................................................13062
Fuel Pump Electrical Circuit........................................................................................................13062
Fuel Rail...........................................................................................................................13062
Idle Air Control (IAC) Valve........................................................................................................13063
Run Mode............................................................................................................................13063
Starting Mode.......................................................................................................................13063
Throttle Body Unit..................................................................................................................13064
General Description (Electronic Ignition System)........................................................................................13064
Camshaft Position (CMP) Sensor......................................................................................................13064
Crankshaft Position (CKP) Sensor....................................................................................................13064
Electronic Ignition.................................................................................................................13065
Ignition Coils......................................................................................................................13065
Ignition Control....................................................................................................................13065
Knock Sensor (KS) PCM Input.........................................................................................................13066
Powertrain Control Module (PCM).....................................................................................................13066
Spark Plug..........................................................................................................................13066
A/C Clutch Diagnosis....................................................................................................................13068
A/C Clutch Circuit Operation........................................................................................................13068
A/C Clutch Circuit Purpose..........................................................................................................13068
A/C Request Signal..................................................................................................................13068
General Description (Evaporative (EVAP) Emission System)................................................................................13069
EVAP Emission Control System Purpose................................................................................................13069
EVAP Emission Control System Operation..............................................................................................13069
Enhanced Evaporative Emission Control System........................................................................................13070
General Description (Exhaust Gas Recirculation (EGR) System)............................................................................13073
EGR Purpose.........................................................................................................................13073
Linear EGR Valve....................................................................................................................13073
Linear EGR Control..................................................................................................................13073
Linear EGR Valve Operation and Results of Incorrect Operation.......................................................................13073
EGR Pintle Position Sensor..........................................................................................................13073
General Description (Positive Crankcase Ventilation (PCV) System).......................................................................13074
Crankcase Ventilation System Purpose................................................................................................13074
Crankcase Ventilation System Operation..............................................................................................13074
Special Tools...........................................................................................................................13075
6F ENGINE EXHAUST.........................................................................................................................13077
General Description.....................................................................................................................13078
Three Way Catalytic Converter LH........................................................................................................13079
Removal.............................................................................................................................13079
Installation........................................................................................................................13079
Three Way Catalytic Converter RH........................................................................................................13080
Removal.............................................................................................................................13080
Installation........................................................................................................................13080
Exhaust Silencer........................................................................................................................13081
Exhaust Silencer and Associated Parts...............................................................................................13081
Removal.............................................................................................................................13081
Installation........................................................................................................................13081
Rear Exhaust pipe.......................................................................................................................13082
Rear Exhaust pipe and Associated Parts..............................................................................................13082
Removal.............................................................................................................................13082
Installation........................................................................................................................13082
Main Data and Specifications............................................................................................................13083
6G ENGINE LUBRICATION.....................................................................................................................13084
Service Precaution......................................................................................................................13084
General Description.....................................................................................................................13085
Oil Pump................................................................................................................................13086
Oil Pump and Associated Parts.......................................................................................................13086
Oil Pump and Associated Parts.......................................................................................................13086
Inspection and Repair...............................................................................................................13087
Reassembly..........................................................................................................................13088
Oil Pan and Crankcase...................................................................................................................13090
Removal.............................................................................................................................13090
Installation........................................................................................................................13090
Oil Pump................................................................................................................................13092
Removal.............................................................................................................................13092
Installation........................................................................................................................13092
Oil Pump Oil Seal.......................................................................................................................13094
Removal.............................................................................................................................13094
Installation........................................................................................................................13094
Oil Filter..............................................................................................................................13095
Removal.............................................................................................................................13095
Installation........................................................................................................................13095
Main Data and Specification.............................................................................................................13096
Special Tool............................................................................................................................13097
6H ENGINE SPEED CONTROL SYSTEM............................................................................................................13098
Service Precaution......................................................................................................................13098
Accelerator Pedal Control Cable.........................................................................................................13099
Removal.............................................................................................................................13099
Inspection..........................................................................................................................13099
Installation........................................................................................................................13099
Accelerator Pedal.......................................................................................................................13100
Accelerator Pedal and Associated Parts..............................................................................................13100
Removal.............................................................................................................................13100
Installation........................................................................................................................13100
6J INDUCTION..............................................................................................................................13101
Service Precaution......................................................................................................................13101
Air Cleaner Element.....................................................................................................................13102
Removal.............................................................................................................................13102
Inspection..........................................................................................................................13102
Installation........................................................................................................................13102
Sec.7 TRANSMISSION............................................................................................................................13198
7A AUTOMATIC TRANSMISSION (4L30-E)........................................................................................................13103
Service Precaution......................................................................................................................13105
Construction............................................................................................................................13105
Range Reference Chart...................................................................................................................13106
Normal Operation Of 1999 4L30-E Transmission............................................................................................13107
Diagnosis...............................................................................................................................13107
Driver Information......................................................................................................................13107
General Diagnosis Procedure.............................................................................................................13110
Preliminary Inspection Chart............................................................................................................13111
Checking Transmission Fluid Level and Condition.........................................................................................13112
Test Driving............................................................................................................................13113
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................13114
Mechanical / Hydraulic Diagnosis Symptoms Index.........................................................................................13115
Stall Test..............................................................................................................................13125
Line Pressure Test......................................................................................................................13125
Shift Speed Chart.......................................................................................................................13126
Lockup Speed Chart......................................................................................................................13128
Changing Transmission Fluid.............................................................................................................13129
Selector Lever..........................................................................................................................13129
Inspection..........................................................................................................................13129
Removal.............................................................................................................................13130
Installation........................................................................................................................13130
Mode Switch.............................................................................................................................13131
Removal.............................................................................................................................13131
Installation........................................................................................................................13131
Transmission (With Transfer Case).......................................................................................................13133
Transmission And Associated Parts...................................................................................................13133
Removal.............................................................................................................................13133
Installation........................................................................................................................13137
Solenoid (Main Case Valve Body).........................................................................................................13141
Removal.............................................................................................................................13141
Installation........................................................................................................................13141
Solenoid (Adapter Case Valve Body)......................................................................................................13142
Removal.............................................................................................................................13142
Installation........................................................................................................................13142
Valve Body Assembly (Main Case).........................................................................................................13143
Removal.............................................................................................................................13143
Installation........................................................................................................................13143
Valve Body Assembly (Adapter Case)......................................................................................................13145
Removal.............................................................................................................................13145
Installation........................................................................................................................13145
Powertrain Control Module (PCM).........................................................................................................13145
Removal.............................................................................................................................13145
Installation........................................................................................................................13145
Speed Sensor (Extension Housing)........................................................................................................13146
Removal.............................................................................................................................13146
Installation........................................................................................................................13146
Transmission Oil Temperature Sensor (Adapter Case)......................................................................................13146
Removal.............................................................................................................................13146
Installation........................................................................................................................13146
Front Oil Seal (Converter Housing)......................................................................................................13147
Removal.............................................................................................................................13147
Installation........................................................................................................................13147
Rear Oil Seal (Extension Housing).......................................................................................................13147
Removal.............................................................................................................................13147
Installation........................................................................................................................13148
Transmission (4L30-E)...................................................................................................................13148
Disassembly.........................................................................................................................13148
Reassembly..........................................................................................................................13152
Converter Housing And Oil Pump Assembly.................................................................................................13163
Disassembled View...................................................................................................................13163
Disassembly.........................................................................................................................13163
Inspection And Repair...............................................................................................................13163
Reassembly..........................................................................................................................13163
Oil Pump................................................................................................................................13164
Disassembled View...................................................................................................................13164
Disassembly.........................................................................................................................13164
Inspection And Repair...............................................................................................................13164
Reassembly..........................................................................................................................13164
Main Case Valve Body....................................................................................................................13165
Disassembled View...................................................................................................................13165
Disassembly.........................................................................................................................13165
Inspection And Repair...............................................................................................................13166
Reassembly..........................................................................................................................13166
Adapter Case Valve Body.................................................................................................................13167
Disassembled View...................................................................................................................13167
Disassembly.........................................................................................................................13167
Inspection And Repair...............................................................................................................13167
Reassembly..........................................................................................................................13167
Third Clutch And Sprag Unit.............................................................................................................13169
Disassembled View...................................................................................................................13169
Disassembly.........................................................................................................................13169
Inspection And Repair...............................................................................................................13170
Reassembly..........................................................................................................................13170
Third Clutch............................................................................................................................13171
Disassembled View...................................................................................................................13171
Disassemble.........................................................................................................................13171
Inspection And Repair...............................................................................................................13171
Reassembly..........................................................................................................................13171
Sprag Unit..............................................................................................................................13173
Disassembled View...................................................................................................................13173
Disassembly.........................................................................................................................13173
Inspection And Repair...............................................................................................................13173
Reassembly..........................................................................................................................13173
Second Clutch...........................................................................................................................13174
Disassembled View...................................................................................................................13174
Disassembly.........................................................................................................................13174
Inspection And Repair...............................................................................................................13175
Reassembly..........................................................................................................................13175
3-4 Accumulator Piston..................................................................................................................13176
Disassembled View...................................................................................................................13176
Disassembly.........................................................................................................................13176
Inspection And Repair...............................................................................................................13176
Reassembly..........................................................................................................................13177
Reverse Clutch Piston And Center Support................................................................................................13178
Disassembled View...................................................................................................................13178
Disassembly.........................................................................................................................13178
Inspection And Repair...............................................................................................................13179
Reassembly..........................................................................................................................13179
Overrun Clutch And Turbine Shaft........................................................................................................13180
Disassembled View...................................................................................................................13180
Disassembly.........................................................................................................................13180
Inspection And Repair...............................................................................................................13181
Reassembly..........................................................................................................................13181
Main Data And Specification.............................................................................................................13183
Special Tools...........................................................................................................................13187
4L30-E Parts List.......................................................................................................................13190
7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)...................................................................................................13198
Service Precaution......................................................................................................................13199
General Description.....................................................................................................................13199
Electronic Control Diagram..........................................................................................................13200
Powertrain Control Module (PCM).....................................................................................................13201
Control System Diagram..............................................................................................................13202
Shift Control.......................................................................................................................13203
Band Apply Control..................................................................................................................13203
Torque Converter Clutch Control.....................................................................................................13203
Line Pressure Control...............................................................................................................13203
On-Board Diagnostic System..........................................................................................................13203
Fail Safe Mechanism.................................................................................................................13203
Torque Management Control...........................................................................................................13203
ATF Warning Control.................................................................................................................13203
ABS Control.........................................................................................................................13203
Shift Mode Control..................................................................................................................13204
Gear Shift Control..................................................................................................................13205
Winter Drive Mode...................................................................................................................13206
Backup Mode.........................................................................................................................13206
Functions of Input / Output Components..............................................................................................13207
Diagnosis...............................................................................................................................13208
Electronic Diagnosis................................................................................................................13208
How To Diagnose The Problem.........................................................................................................13208
Check Trans Indicator...............................................................................................................13208
Diagnostic Check....................................................................................................................13208
"Check Trans" Check.................................................................................................................13209
Tech 2 OBD II Connection............................................................................................................13210
F0: Transmission Data...............................................................................................................13214
F1: PC Solenoid Data................................................................................................................13215
OBD II Diagnostic Management System.................................................................................................13216
16-Terminal Data Link Connector (DLC)...............................................................................................13217
Malfunction Indicator Lamp (MIL)....................................................................................................13218
Types Of Diagnostic Trouble Codes (DTCs)............................................................................................13218
Clear DTC...........................................................................................................................13218
DTC Check...........................................................................................................................13219
PCM Precaution......................................................................................................................13219
Information On PCM..................................................................................................................13219
Intermittent Conditions.............................................................................................................13219
Transmission And PCM Identification.................................................................................................13220
Diagnostic Trouble Code (DTC) Identification........................................................................................13221
DTC P0218 Transmission Fluid Over Temperature...........................................................................................13222
DTC P0560 System Voltage Malfunction....................................................................................................13224
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position......................................................................13227
DTC P0706 Transmission Range Switch (Mode Switch) Performance...........................................................................13230
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Circuit Range/Performance.........................................................13233
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input.................................................................13236
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................13239
DTC P0719 TCC Brake Switch Circuit High (Stuck On)......................................................................................13242
DTC P0722 Transmission Output Speed Sensor (OSS) Low Input..............................................................................13245
DTC P0723 Transmission Output Speed Sensor (OSS) Intermittent...........................................................................13248
DTC P0724 TCC Brake Switch Circuit Low (Stuck Off)......................................................................................13251
DTC P0730 Transmission Incorrect Gear Ratio.............................................................................................13253
DTC P0742 Torque Converter Clutch (TCC) Circuit Stuck On................................................................................13256
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical..............................................................13258
DTC P0751 Shift Solenoid A Performance Without Input Speed..............................................................................13260
DTC P0753 Shift Solenoid A Electrical...................................................................................................13262
DTC P0756 Shift Solenoid B Performance Without Input Speed..............................................................................13265
DTC P0758 Shift Solenoid B Electrical...................................................................................................13267
DTC P1790 ROM Transmission Side Bad Check Sum...........................................................................................13271
DTC P1792 EEPROM Transmission Side Bad Check Sum........................................................................................13272
DTC P1835 Kickdown Switch Always On.....................................................................................................13273
DTC P1850 Brake Band Apply Solenoid Malfunction.........................................................................................13275
DTC P1860 TCC Solenoid Electrical.......................................................................................................13279
DTC P1870 Transmission Component Slipping...............................................................................................13282
Circuit Diagram.........................................................................................................................13284
Parts Location..........................................................................................................................13286
Harness Connector Faces.................................................................................................................13287
Sec.8 BODY AND ACCESSORIES....................................................................................................................13289
8A LIGHTING SYSTEM........................................................................................................................13289
Service Precaution......................................................................................................................13290
Headlight Bulb..........................................................................................................................13290
Removal.............................................................................................................................13290
Installation........................................................................................................................13290
Headlight...............................................................................................................................13291
Removal.............................................................................................................................13291
Installation........................................................................................................................13291
Headlight Adjustment................................................................................................................13291
Fender Marker Light Bulb................................................................................................................13293
Removal.............................................................................................................................13293
Installation........................................................................................................................13293
Front Side Marker Light Bulb............................................................................................................13293
Removal.............................................................................................................................13293
Installation........................................................................................................................13293
Rear Side Marker Light Bulb.............................................................................................................13294
Removal.............................................................................................................................13294
Installation........................................................................................................................13294
Parking Light Bulb......................................................................................................................13294
Removal.............................................................................................................................13294
Installation........................................................................................................................13294
Taillight Bulb..........................................................................................................................13295
Removal.............................................................................................................................13295
Installation........................................................................................................................13295
License Plate Light Bulb................................................................................................................13295
Removal.............................................................................................................................13295
Installation........................................................................................................................13295
Stoplight Bulb..........................................................................................................................13296
Removal and Installation............................................................................................................13296
High Mounted Stop Light.................................................................................................................13296
Removal.............................................................................................................................13296
Installation........................................................................................................................13296
Front Turn Signal Light Bulb............................................................................................................13297
Removal.............................................................................................................................13297
Installation........................................................................................................................13297
Rear Turn Signal Light Bulb.............................................................................................................13297
Removal.............................................................................................................................13297
Installation........................................................................................................................13297
Backup Light Bulb.......................................................................................................................13298
Removal.............................................................................................................................13298
Installation........................................................................................................................13298
Dome Light Bulb.........................................................................................................................13298
Removal.............................................................................................................................13298
Installation........................................................................................................................13298
Map Light Switch/Bulb...................................................................................................................13299
Removal.............................................................................................................................13299
Installation........................................................................................................................13299
Cigarette Lighter Illumination Bulb.....................................................................................................13299
Removal.............................................................................................................................13299
Installation........................................................................................................................13299
Ashtray Illumination Bulb...............................................................................................................13300
Removal.............................................................................................................................13300
Installation........................................................................................................................13300
HVAC Bezel Illumination Light Bulb......................................................................................................13300
Removal and Installation............................................................................................................13300
Shift Lever Illumination Light Bulb (A/T)...............................................................................................13301
Removal.............................................................................................................................13301
Installation........................................................................................................................13301
Starter Switch..........................................................................................................................13301
Removal.............................................................................................................................13301
Installation........................................................................................................................13301
Lighting Switch (Combination Switch)....................................................................................................13302
Removal.............................................................................................................................13302
Installation........................................................................................................................13302
Stoplight Switch........................................................................................................................13303
Removal.............................................................................................................................13303
Installation........................................................................................................................13303
Turn Signal Switch(Combination Switch)..................................................................................................13304
Removal and Installation............................................................................................................13304
Hazard Warning Switch...................................................................................................................13304
Removal.............................................................................................................................13304
Installation........................................................................................................................13304
Key Remind Switch(Starter Switch).......................................................................................................13304
Removal and Installation............................................................................................................13304
Door Switch.............................................................................................................................13305
Removal.............................................................................................................................13305
Installation........................................................................................................................13305
Rear Defogger Switch....................................................................................................................13305
Removal.............................................................................................................................13305
Installation........................................................................................................................13305
Illumination Controller.................................................................................................................13306
Removal.............................................................................................................................13306
Installation........................................................................................................................13306
Main Data and Specifications............................................................................................................13307
8B WIPER / WASHER SYSTEM..................................................................................................................13310
Service Precaution......................................................................................................................13310
Windshield Wiper/Washer System..........................................................................................................13311
General Description.................................................................................................................13311
Windshield Wiper And Washer Switch......................................................................................................13311
Removal and Installation............................................................................................................13311
Windshield Wiper Motor..................................................................................................................13311
Removal.............................................................................................................................13311
Installation........................................................................................................................13311
Windshield Washer Motor.................................................................................................................13312
Removal.............................................................................................................................13312
Installation........................................................................................................................13312
Washer Nozzle Angle Adjustment......................................................................................................13312
Windshield Wiper Linkage................................................................................................................13313
Windshield Wiper Linkage and Associated Parts.......................................................................................13313
Removal.............................................................................................................................13313
Installation........................................................................................................................13313
Windshield Wiper Arm/Blade..............................................................................................................13314
Removal.............................................................................................................................13314
Installation........................................................................................................................13314
Windshield Wiper Blade Rubber...........................................................................................................13315
Removal.............................................................................................................................13315
Installation........................................................................................................................13315
Alarm & Relay Control Unit..............................................................................................................13316
Removal.............................................................................................................................13316
Installation........................................................................................................................13316
Intermittent Relay......................................................................................................................13316
Removal.............................................................................................................................13316
Installation........................................................................................................................13316
Main Data and Specifications............................................................................................................13317
8C ENTERTAINMENT..........................................................................................................................13318
Service Precaution......................................................................................................................13318
Cigarette Lighter.......................................................................................................................13319
General Description.................................................................................................................13319
Removal.............................................................................................................................13319
Installation........................................................................................................................13319
Antenna.................................................................................................................................13320
Removal.............................................................................................................................13320
Installation........................................................................................................................13320
Radio...................................................................................................................................13321
Removal.............................................................................................................................13321
Installation........................................................................................................................13321
Front Speaker...........................................................................................................................13321
Removal.............................................................................................................................13321
Installation........................................................................................................................13321
Tweeter Assembly........................................................................................................................13322
Removal.............................................................................................................................13322
Installation........................................................................................................................13322
Rear Speaker............................................................................................................................13322
Removal.............................................................................................................................13322
Installation........................................................................................................................13322
Horn (Low note).........................................................................................................................13323
Removal.............................................................................................................................13323
Installation........................................................................................................................13323
Horn (High note)........................................................................................................................13323
Removal.............................................................................................................................13323
Installation........................................................................................................................13323
8D WIRING SYSTEM..........................................................................................................................13324
Fuse, Relay and Diode...................................................................................................................13325
Relay and Fuse Box / Relay Box Location.............................................................................................13325
Fuse Layout.........................................................................................................................13326
Relay Layout........................................................................................................................13327
Diode Layout........................................................................................................................13328
Circuit Diagram.........................................................................................................................13329
Harness and Connector Location..........................................................................................................13353
8E METER AND GAUGE........................................................................................................................13372
Service Precaution......................................................................................................................13372
Meter Assembly..........................................................................................................................13373
General Description.................................................................................................................13373
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights..................................................13373
Table for Meter/Gauge Connector Terminal Connections................................................................................13375
Removal.............................................................................................................................13377
Installation........................................................................................................................13377
Speedometer.............................................................................................................................13378
Removal.............................................................................................................................13378
Installation........................................................................................................................13378
Tachometer..............................................................................................................................13379
Removal.............................................................................................................................13379
Installation........................................................................................................................13379
Coolant Temperature gauge and Fuel Gauge................................................................................................13380
Removal.............................................................................................................................13380
Installation........................................................................................................................13380
TOD Indicator Assembly..................................................................................................................13381
Removal.............................................................................................................................13381
Installation........................................................................................................................13381
Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb.......................................................................13382
Removal.............................................................................................................................13382
Installation........................................................................................................................13382
A/T Indicator Light Bulb................................................................................................................13382
Removal.............................................................................................................................13382
Installation........................................................................................................................13382
Vehicle Speed Sensor....................................................................................................................13383
Removal.............................................................................................................................13383
Installation........................................................................................................................13383
Thermo Unit.............................................................................................................................13383
Removal.............................................................................................................................13383
Installation........................................................................................................................13383
Fuel Tank Unit..........................................................................................................................13384
Removal.............................................................................................................................13384
Installation........................................................................................................................13384
Main Data and Specifications............................................................................................................13385
8F BODY STRUCTURE.........................................................................................................................13386
Service Precaution......................................................................................................................13387
Frame...................................................................................................................................13387
General Description.................................................................................................................13387
Frame Dimensions....................................................................................................................13388
Front Bumper............................................................................................................................13389
Parts Location......................................................................................................................13389
Removal.............................................................................................................................13390
Installation........................................................................................................................13390
Rear Bumper.............................................................................................................................13391
Parts Location......................................................................................................................13391
Removal.............................................................................................................................13391
Installation........................................................................................................................13391
Engine Hood.............................................................................................................................13392
Parts Location......................................................................................................................13392
Removal.............................................................................................................................13392
Installation........................................................................................................................13393
Engine Hood Cover.......................................................................................................................13394
Parts Location......................................................................................................................13394
Removal.............................................................................................................................13394
Installation........................................................................................................................13394
Engine Hood Lock........................................................................................................................13395
Parts Location......................................................................................................................13395
Removal.............................................................................................................................13395
Installation........................................................................................................................13396
Radiator Grille.........................................................................................................................13396
Parts Location......................................................................................................................13396
Removal.............................................................................................................................13396
Installation........................................................................................................................13396
Front Fender Panel......................................................................................................................13397
Parts Location......................................................................................................................13397
Removal.............................................................................................................................13397
Installation........................................................................................................................13398
Body Mounting...........................................................................................................................13399
Parts Location......................................................................................................................13399
Tightening Torque...................................................................................................................13399
Body Dimension......................................................................................................................13400
Instrument Panel Assembly and Cross Beam Assembly.......................................................................................13410
Parts Location......................................................................................................................13410
Removal.............................................................................................................................13411
Installation........................................................................................................................13414
Front Door Assembly.....................................................................................................................13416
Parts Location......................................................................................................................13416
Removal.............................................................................................................................13416
Installation........................................................................................................................13417
Door Strikers...........................................................................................................................13418
Adjustment..........................................................................................................................13418
Front Window Regulator, Glass and Glass Run.............................................................................................13419
Parts Location......................................................................................................................13419
Removal.............................................................................................................................13420
Installation........................................................................................................................13422
Tailgate Assembly.......................................................................................................................13423
Parts Location......................................................................................................................13423
Removal.............................................................................................................................13423
Installation........................................................................................................................13424
Tailgate Dove-Tail......................................................................................................................13425
Parts Location......................................................................................................................13425
Removal.............................................................................................................................13425
Installation........................................................................................................................13425
Spare Tire Carrier......................................................................................................................13426
Parts Location......................................................................................................................13426
Removal.............................................................................................................................13426
Installation........................................................................................................................13426
Windshield..............................................................................................................................13427
Parts Location......................................................................................................................13427
Removal.............................................................................................................................13427
Installation........................................................................................................................13428
Rear Quarter............................................................................................................................13432
Parts Location......................................................................................................................13432
Removal.............................................................................................................................13432
Installation........................................................................................................................13433
Center Glass............................................................................................................................13434
Parts Location......................................................................................................................13434
Removal.............................................................................................................................13434
Installation........................................................................................................................13435
Tailgate Glass..........................................................................................................................13436
Parts Location......................................................................................................................13436
Removal.............................................................................................................................13436
Installation........................................................................................................................13436
Main Data and Specifications............................................................................................................13438
8G SEATS..................................................................................................................................13439
Service Precaution......................................................................................................................13439
Front Seat Assembly.....................................................................................................................13440
Disassembled View...................................................................................................................13440
Removal.............................................................................................................................13440
Installation........................................................................................................................13441
Disassembly.........................................................................................................................13441
Reassembly..........................................................................................................................13441
Rear Seat Assembly......................................................................................................................13442
Disassembled View...................................................................................................................13442
Removal.............................................................................................................................13442
Installation........................................................................................................................13442
Disassembly.........................................................................................................................13443
Reassembly..........................................................................................................................13443
Main Data and Specifications............................................................................................................13444
8H SECURITY AND LOCKS.....................................................................................................................13445
Service Precaution......................................................................................................................13445
Front Door Lock Assembly................................................................................................................13446
Front Door Lock Assembly and Associated Parts.......................................................................................13446
Removal.............................................................................................................................13446
Installation........................................................................................................................13447
Front Outside Handle and Door Lock Cylinder.............................................................................................13448
Front Outside Handle, Door Lock Cylinder and Associated Parts.......................................................................13448
Removal.............................................................................................................................13448
Installation........................................................................................................................13449
Tailgate Lock and Lock Cylinder.........................................................................................................13450
Tailgate Lock, Lock Cylinder and Associated Parts...................................................................................13450
Removal.............................................................................................................................13450
Installation........................................................................................................................13451
Key.....................................................................................................................................13452
Key Coding..........................................................................................................................13452
Key Styles..........................................................................................................................13452
Power Door Lock System..................................................................................................................13453
General Description.................................................................................................................13453
Front Door Lock Actuator Removal....................................................................................................13453
Front Door Lock Actuator Installation...............................................................................................13453
Main Data and Specifications............................................................................................................13454
8J EXTERIOR / INTERIOR TRIM...............................................................................................................13455
Service Precaution......................................................................................................................13455
Consoles................................................................................................................................13456
Consoles and Associated Parts.......................................................................................................13456
Removal.............................................................................................................................13456
Installation........................................................................................................................13456
Front Door Trim Assembly................................................................................................................13457
Front Door Trim Assembly and Associated Parts.......................................................................................13457
Removal.............................................................................................................................13457
Installation........................................................................................................................13458
Door Mirror.............................................................................................................................13458
Door Mirror and Associated Parts....................................................................................................13458
Removal.............................................................................................................................13458
Installation........................................................................................................................13458
Interior Trim Cover and Assist Grip.....................................................................................................13459
Interior Trim Cover, Assist Grip and Associated Parts...............................................................................13459
Removal.............................................................................................................................13459
Installation........................................................................................................................13460
Headlining..............................................................................................................................13461
Parts Location......................................................................................................................13461
Removal.............................................................................................................................13461
Installation........................................................................................................................13462
Tailgate Trim Cover.....................................................................................................................13462
Tailgate Trim Cover and Associated Parts............................................................................................13462
Removal.............................................................................................................................13462
Installation........................................................................................................................13462
Body Side Protectors....................................................................................................................13463
Body Side Protectors and Associated Parts...........................................................................................13463
Removal.............................................................................................................................13464
Installation........................................................................................................................13464
Tailgate Protector......................................................................................................................13465
Parts Location......................................................................................................................13465
Removal.............................................................................................................................13465
Installation........................................................................................................................13465
Fuel Filler Lid.........................................................................................................................13466
Parts Location......................................................................................................................13466
Removal.............................................................................................................................13466
Installation........................................................................................................................13466
Roof Rail Assembly......................................................................................................................13467
Parts Location......................................................................................................................13467
Removal.............................................................................................................................13467
Installation........................................................................................................................13467
Rear Roof Spoiler.......................................................................................................................13468
Parts Location......................................................................................................................13468
Removal.............................................................................................................................13468
Installation........................................................................................................................13468
Power Door Mirror System................................................................................................................13469
General Description.................................................................................................................13469
Door Mirror Control Switch and Door Mirror Defogger Switch Removal..................................................................13469
Installation........................................................................................................................13469
Power Door Mirror.......................................................................................................................13469
General Description.................................................................................................................13469
Removal and Installation............................................................................................................13469
Power Window System.....................................................................................................................13470
General Description.................................................................................................................13470
Power Window Switch Removal and Installation........................................................................................13470
Power Window Motor Removal and Installation.........................................................................................13471
Main Data and Specifications............................................................................................................13472
Sec.9 RESTRAINTS..............................................................................................................................13530
9A SEAT BELT SYSTEM.......................................................................................................................13473
Service Precaution......................................................................................................................13473
Front Seat Belt.........................................................................................................................13474
Front Seat Belt and Associated Parts................................................................................................13474
Removal.............................................................................................................................13474
Inspection..........................................................................................................................13474
Installation........................................................................................................................13475
Rear Seat Belt..........................................................................................................................13476
Rear Seat Belt and Associated Parts.................................................................................................13476
Removal.............................................................................................................................13476
Inspection..........................................................................................................................13477
Installation........................................................................................................................13477
Front Seat Belt Buckle Assembly.........................................................................................................13478
Front Seat Belt Buckle Assembly and Associated Parts................................................................................13478
Removal.............................................................................................................................13478
Installation........................................................................................................................13478
Rear Seat Belt Buckle Assembly..........................................................................................................13479
Removal.............................................................................................................................13479
Installation........................................................................................................................13479
Child Seat Tether Anchor Bracket (Child Restraint)......................................................................................13480
General Description.................................................................................................................13480
Child Seat Tether Anchor Bracket and Associated Parts...............................................................................13480
Installation........................................................................................................................13480
Main Data and Specifications............................................................................................................13481
9J SUPPLEMENTAL RESTRAINT SYSTEM..........................................................................................................13482
Service Precaution......................................................................................................................13482
General Description.....................................................................................................................13483
SRS Component and Wiring Location View..............................................................................................13485
Component Description...................................................................................................................13485
Definition..............................................................................................................................13488
Diagnosis...............................................................................................................................13489
SRS Connector Body Face Views...........................................................................................................13490
Repairs and Inspections Required After an Accident......................................................................................13490
On-Vehicle Service......................................................................................................................13491
Air Bag Assembly Handling / Shipping / Scrapping........................................................................................13492
Special Tools...........................................................................................................................13508
Service Precaution......................................................................................................................13513
Sensing and Diagnostic Module (SDM).....................................................................................................13515
Service Precautions.................................................................................................................13515
Removal.............................................................................................................................13515
Installation........................................................................................................................13515
Driver Air Bag Assembly.................................................................................................................13517
Service Precautions.................................................................................................................13517
Removal.............................................................................................................................13517
Installation........................................................................................................................13517
Steering Wheel..........................................................................................................................13518
Service Precautions.................................................................................................................13518
Removal.............................................................................................................................13518
Installation........................................................................................................................13519
SRS Coil Assembly.......................................................................................................................13520
Service Precaution..................................................................................................................13520
Removal.............................................................................................................................13520
Installation........................................................................................................................13521
Steering Column.........................................................................................................................13523
Service Precaution..................................................................................................................13523
Removal.............................................................................................................................13523
Installation........................................................................................................................13525
Passenger Air Bag Assembly..............................................................................................................13527
Service Precaution..................................................................................................................13527
Removal.............................................................................................................................13527
Installation........................................................................................................................13527
Main Data and Specifications............................................................................................................13528
SRS Air Bag System Inspection Standards For Repair......................................................................................13529
9J1 SRS CONTROL SYSTEM.....................................................................................................................13530
Service Precaution......................................................................................................................13530
Diagnostic Information..................................................................................................................13531
Parts For Electrical Circuit............................................................................................................13533
System Schematic........................................................................................................................13534
SRS Diagnostic System Check.............................................................................................................13534
Chart A SDM Integrity Check.............................................................................................................13537
Chart B "AIR BAG" Warning Lamp Comes "ON" Steady........................................................................................13539
Chart C "AIR BAG" Warning Lamp Does Not Comes "ON" Steady...............................................................................13541
DTC 15 Passenger Deployment Loop Resistance High........................................................................................13544
DTC 16 Passenger Deployment Loop Resistance Low.........................................................................................13547
DTC 17 Passenger Deployment Loop Open...................................................................................................13550
DTC 18 Passenger Deployment Loop Short To Ground........................................................................................13552
DTC 19 Passenger Deployment Loop Short To Voltage.......................................................................................13554
DTC 21 Driver Deployment Loop Resistance High...........................................................................................13556
DTC 22 Driver Deployment Loop Resistance Low............................................................................................13559
DTC 24 Driver Deployment Loop Short To Ground...........................................................................................13562
DTC 25 Driver Deployment Loop Short To Voltage..........................................................................................13564
DTC 26 Driver Deployment Loop Open......................................................................................................13567
DTC 51 Deployment Event Commanded.......................................................................................................13570
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range..................................................13572
DTC 61 Warning Lamp Circuit Failure.....................................................................................................13574
DTC 71 Internal SDM Fault...............................................................................................................13576
Sec.10 CONTROL SYSTEM..........................................................................................................................13578
10A CRUISE CONTROL SYSTEM..................................................................................................................13578
Service Precaution......................................................................................................................13578
General Description.....................................................................................................................13579
Diagnosis...............................................................................................................................13579
Brake Switch............................................................................................................................13580
Removal and Installation............................................................................................................13580
Adjustment..........................................................................................................................13580
Cruise Control Unit.....................................................................................................................13580
Removal.............................................................................................................................13580
Installation........................................................................................................................13580
Cruise Actuator.........................................................................................................................13581
Actuator Cable Diagram..............................................................................................................13581
Removal.............................................................................................................................13581
Installation........................................................................................................................13582
Adjustment..........................................................................................................................13582
Mode Switch.............................................................................................................................13583
Removal and Installation............................................................................................................13583
Cruise Control Main Switch..............................................................................................................13583
Removal.............................................................................................................................13583
Installation........................................................................................................................13583
Cruise Control Switch (Combination Switch)..............................................................................................13583
Removal and Installation............................................................................................................13583
2001 MODEL.............................................................................................................................................. 2
(UE) RODEO..........................................................................................................................................13584
Sec.0 GENERAL INFORMATION.......................................................................................................................13585
0A GENERAL INFORMATION......................................................................................................................13585
GENERAL INFORMATION.....................................................................................................................13585
Illustration Arrows.....................................................................................................................13586
Identification..........................................................................................................................13587
Theft Prevention Standard...............................................................................................................13590
Lifting Instructions....................................................................................................................13595
Standard Bolts Torque Specifications....................................................................................................13597
Abbreviations Charts....................................................................................................................13598
Service Parts Identification Plate......................................................................................................13599
0B Maintenance and Lubrication..............................................................................................................13600
Maintenance and Lubrication.............................................................................................................13600
Explanation of Complete Vehicle Maintenance Schedule....................................................................................13604
Recommended Fluids and Lubricants...................................................................................................13607
Lubricant Viscosity Chart...............................................................................................................13608
Recommended Liquid Gasket...........................................................................................................13610
Recommended Thread Locking
Agents...................................................................................................13610
Maintenance Service Data................................................................................................................13611
Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)..........................................................................................13612
1A HVAC SYSTEMS.............................................................................................................................13612
Service Precaution......................................................................................................................13613
Heating and Ventilation System..........................................................................................................13613
General Description.....................................................................................................................13613
Wiring Diagram..........................................................................................................................13617
Diagnosis...............................................................................................................................13618
Individual Inspection...................................................................................................................13622
Heater Unit.............................................................................................................................13624
Heater Unit and Associated Parts....................................................................................................13624
Removal.............................................................................................................................13624
Installation........................................................................................................................13625
Heater Core and / or Mode Door..........................................................................................................13625
Disassembled View...................................................................................................................13625
Removal.............................................................................................................................13626
Inspection..........................................................................................................................13626
Installation........................................................................................................................13626
Heater Mode Control Link Unit...........................................................................................................13627
Disassembled View...................................................................................................................13627
Removal.............................................................................................................................13627
Installation........................................................................................................................13628
Heater Temperature Control Link Unit....................................................................................................13628
Disassembled View...................................................................................................................13628
Removal.............................................................................................................................13628
Installation........................................................................................................................13629
Blower Assembly.........................................................................................................................13629
Blower Assembly and Associated Parts................................................................................................13629
Removal.............................................................................................................................13630
Installation........................................................................................................................13630
Blower Link Unit and / or Mode door.....................................................................................................13630
Disassembled View...................................................................................................................13630
Removal.............................................................................................................................13630
Installation........................................................................................................................13631
Blower Motor............................................................................................................................13632
Blower Motor and Associated Parts...................................................................................................13632
Removal.............................................................................................................................13632
Installation........................................................................................................................13632
Rear Heater Duct, Defroster Nozzle and Ventilation Duct.................................................................................13633
Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts...........................................................13633
Removal.............................................................................................................................13633
Installation........................................................................................................................13634
Control Lever Assembly and / or Control Cable...........................................................................................13634
Control Lever Assembly, Control Cable and Associated Parts..........................................................................13634
Removal.............................................................................................................................13635
Installation........................................................................................................................13636
Control Panel Illumination Bulb.........................................................................................................13637
Control Panel Illumination Bulb and Associated Parts................................................................................13637
Removal.............................................................................................................................13637
Installation........................................................................................................................13637
Resistor................................................................................................................................13637
Resistor and Associated Parts.......................................................................................................13637
Removal.............................................................................................................................13637
Installation........................................................................................................................13637
Air Conditioning System.................................................................................................................13638
General Description.....................................................................................................................13638
Diagnosis...............................................................................................................................13648
Air Source Select Lever Diagnosis.......................................................................................................13658
Air Conditioning System.................................................................................................................13661
Individual Inspection...................................................................................................................13661
General Repair Procedure............................................................................................................13662
Leak Check..........................................................................................................................13664
Compressor Assembly.....................................................................................................................13669
Compressor Assembly and Associated Parts (6VD1).....................................................................................13669
Removal.............................................................................................................................13669
Installation........................................................................................................................13670
New Compressor Installation.........................................................................................................13670
Compressor Assembly.....................................................................................................................13671
Compressor Assembly and Associated Parts (X22SE)....................................................................................13671
Removal.............................................................................................................................13671
Installation........................................................................................................................13672
New Compressor Installation.........................................................................................................13672
Condenser Assembly......................................................................................................................13673
Condenser Assembly and Associated Parts.............................................................................................13673
Removal.............................................................................................................................13673
Installation........................................................................................................................13673
Condenser Fan Motor.....................................................................................................................13674
Condenser Fan Motor and Associated Parts............................................................................................13674
Removal.............................................................................................................................13674
Installation........................................................................................................................13674
Receiver / Drier........................................................................................................................13675
Receiver / Drier and Associated Parts...............................................................................................13675
Removal.............................................................................................................................13675
Installation........................................................................................................................13675
Pressure Switch.........................................................................................................................13676
Pressure Switch and Associated Parts................................................................................................13676
Removal.............................................................................................................................13676
Installation........................................................................................................................13676
Evaporator Assembly.....................................................................................................................13677
Evaporator Assembly and Associated Parts............................................................................................13677
Removal.............................................................................................................................13677
Installation........................................................................................................................13678
Electronic Thermostat, Evaporator Core and/or Expansion Valve...........................................................................13679
Disassembled View...................................................................................................................13679
Removal.............................................................................................................................13679
Installation........................................................................................................................13680
Refrigerant Line........................................................................................................................13681
Refrigerant Line and Associated Parts...............................................................................................13681
Removal.............................................................................................................................13681
Installation........................................................................................................................13682
Main Data And Specifications............................................................................................................13683
Compressor..............................................................................................................................13686
Service Precaution..................................................................................................................13686
General Description.....................................................................................................................13686
Diagnosis...............................................................................................................................13687
Magnetic Clutch Assembly (DKV-14G Type).................................................................................................13688
Parts Location View.................................................................................................................13688
Removal.............................................................................................................................13688
Inspection and Repair...............................................................................................................13690
Installation........................................................................................................................13690
Compressor Oil..........................................................................................................................13692
Oil Specification...................................................................................................................13692
Handling of Oil.....................................................................................................................13692
Compressor Oil Check................................................................................................................13692
Checking and Adjusting Oil Quantity for Used Compressor.............................................................................13692
Checking and Adjusting for Compressor Replacement...................................................................................13693
Contamination of Compressor Oil.....................................................................................................13693
Oil Return Operation................................................................................................................13693
Replacement of Component Parts......................................................................................................13693
Main Data and Specifications............................................................................................................13694
Special Tools...........................................................................................................................13696
Sec.2 STEERING..................................................................................................................................13697
2A POWER-ASSISTED STEERING SYSTEM...........................................................................................................13697
Service Precaution......................................................................................................................13698
Diagnosis...............................................................................................................................13698
General Description.....................................................................................................................13704
Power Steering System Test..............................................................................................................13706
Maintenance.............................................................................................................................13707
Fluid Level.............................................................................................................................13707
Bleeding The Power Steering System......................................................................................................13707
Bleeding Procedure......................................................................................................................13707
Flushing The Power Steering System......................................................................................................13707
Steering Wheel Free Play Inspection.....................................................................................................13708
Front End Alignment Inspection and
Adjustment...........................................................................................13708
Main Data and Specifications............................................................................................................13712
Special Tools.......................................................................................................................13713
Power Steering Unit.....................................................................................................................13714
Power Steering Unit and Associated Parts............................................................................................13714
Removal.............................................................................................................................13714
Installation (4×2 Model)............................................................................................................13715
Installation (4×4 Model)............................................................................................................13715
Power Steering Unit Disassembled View...............................................................................................13716
Disassembly.........................................................................................................................13716
Inspection and Repair...............................................................................................................13716
Reassembly..........................................................................................................................13716
Main Data and Specifications........................................................................................................13717
Special Tools.......................................................................................................................13717
Power Steering Pump.....................................................................................................................13718
Power Steering Pump and Associated Parts............................................................................................13718
Removal.............................................................................................................................13718
Installation........................................................................................................................13718
Power Steering Pump Disassembled View...............................................................................................13719
Disassembly.........................................................................................................................13719
Inspection and Repair...............................................................................................................13720
Reassembly..........................................................................................................................13720
Main Data and Specifications............................................................................................................13722
Transfer Gear Assembly..................................................................................................................13723
Transfer Gear Assembly and Associated Parts.........................................................................................13723
Removal.............................................................................................................................13723
Inspection and Repair...............................................................................................................13723
Installation........................................................................................................................13723
Supplemental Restraint System Steering Wheel & Column...................................................................................13724
Service Precaution..................................................................................................................13724
SRS Connectors......................................................................................................................13724
Inflator Module.........................................................................................................................13726
Inflator Module and Associated Parts................................................................................................13726
Removal.............................................................................................................................13726
Inspection and Repair...............................................................................................................13727
Installation........................................................................................................................13727
Steering Wheel..........................................................................................................................13728
Steering Wheel and Associated Parts.................................................................................................13728
Removal.............................................................................................................................13728
Installation........................................................................................................................13730
Combination Switch......................................................................................................................13731
Combination Switch and Associated Parts.............................................................................................13731
Removal.............................................................................................................................13731
Installation........................................................................................................................13733
Lock Cylinder...........................................................................................................................13735
Lock Cylinder and Associated Parts..................................................................................................13735
Removal.............................................................................................................................13735
Installation........................................................................................................................13737
System Inspection...................................................................................................................13738
Steering Column.........................................................................................................................13739
Steering Column and Associated Parts................................................................................................13739
Removal.............................................................................................................................13739
Insepction..........................................................................................................................13741
Installation........................................................................................................................13743
System Inspection...................................................................................................................13744
Supplemental Restraint System Steering Wheel & Column and
Associated Parts..............................................................13745
Main Data and Specifications............................................................................................................13745
Special Tools.......................................................................................................................13745
Sec.3 SUSPENSION................................................................................................................................13746
3C FRONT SUSPENSION.........................................................................................................................13746
Service Precaution......................................................................................................................13746
General Description.....................................................................................................................13747
Diagnosis...............................................................................................................................13747
Shock Absorber..........................................................................................................................13750
Shock Absorber and Associated Parts.................................................................................................13750
Removal.............................................................................................................................13750
Inspection and Repair...............................................................................................................13750
Installation........................................................................................................................13750
Stabilizer Bar..........................................................................................................................13751
Stabilizer Bar and Associated Parts.................................................................................................13751
Removal.............................................................................................................................13751
Inspection and Repair...............................................................................................................13751
Installation........................................................................................................................13751
Torsion Bar.............................................................................................................................13752
Torsion Bar and Associated Parts....................................................................................................13752
Removal.............................................................................................................................13752
Inspection and Repair...............................................................................................................13753
Installation........................................................................................................................13753
Knuckle.................................................................................................................................13755
Knuckle and Associated Parts........................................................................................................13755
Removal.............................................................................................................................13755
Inspection and Repair...............................................................................................................13756
Installation........................................................................................................................13756
Upper Control Arm.......................................................................................................................13758
Upper Control Arm and Associated Parts..............................................................................................13758
Removal.............................................................................................................................13758
Inspection and Repair...............................................................................................................13759
Installation........................................................................................................................13759
Lower Control Arm.......................................................................................................................13761
Lower Control Arm and Associated Parts..............................................................................................13761
Removal.............................................................................................................................13761
Inspection and Repair...............................................................................................................13762
Installation........................................................................................................................13763
Upper Ball Joint........................................................................................................................13764
Upper Ball Joint and Associated Parts...............................................................................................13764
Removal.............................................................................................................................13764
Inspection and Repair...............................................................................................................13765
Installation........................................................................................................................13765
Lower Ball Joint........................................................................................................................13766
Lower Ball Joint and Associated Parts...............................................................................................13766
Removal.............................................................................................................................13766
Inspection and Repair...............................................................................................................13767
Installation........................................................................................................................13767
Main Data and Specifications............................................................................................................13768
Special Tools.......................................................................................................................13770
3D REAR SUSPENSION..........................................................................................................................13771
Service Precaution......................................................................................................................13771
General Description.....................................................................................................................13771
Diagnosis...............................................................................................................................13772
Coil Spring.............................................................................................................................13775
Coil Spring and Associated Parts....................................................................................................13775
Removal.............................................................................................................................13775
Inspection and Repair...............................................................................................................13776
Installation........................................................................................................................13776
Shock Absorber..........................................................................................................................13777
Shock Absorber and Associated Parts.................................................................................................13777
Removal.............................................................................................................................13777
Inspection and Repair...............................................................................................................13777
Installation........................................................................................................................13777
Trailing Link...........................................................................................................................13778
Trailing Link and Associated Parts..................................................................................................13778
Removal.............................................................................................................................13778
Inspection and Repair...............................................................................................................13778
Installation........................................................................................................................13779
Upper Link..............................................................................................................................13780
Upper Link and Associated Parts.....................................................................................................13780
Removal.............................................................................................................................13780
Inspection and Repair...............................................................................................................13780
Installation........................................................................................................................13781
Lateral Rod.............................................................................................................................13782
Lateral Rod and Associated Parts....................................................................................................13782
Removal.............................................................................................................................13782
Inspection and Repair...............................................................................................................13782
Installation........................................................................................................................13783
Stabilizer Bar..........................................................................................................................13784
Stabilizer Bar and Associated Parts.................................................................................................13784
Removal.............................................................................................................................13784
Inspection and Repair...............................................................................................................13784
Installation........................................................................................................................13785
Main Data and Specifications............................................................................................................13786
Special Tools...........................................................................................................................13788
3E WHEEL AND TIRE SYSTEM....................................................................................................................13789
Service Precaution......................................................................................................................13789
General Description.....................................................................................................................13790
Diagnosis...............................................................................................................................13791
Wheel...................................................................................................................................13799
Wheel and Associated Parts..........................................................................................................13799
Removal.............................................................................................................................13799
Installation........................................................................................................................13799
Tire....................................................................................................................................13800
Tire Replacement....................................................................................................................13800
General Balance Procedure...........................................................................................................13800
Balancing Wheel and Tire............................................................................................................13801
Main Data and Specifications............................................................................................................13802
3F SUSPENSION...............................................................................................................................13803
Service Precaution......................................................................................................................13804
General Description.....................................................................................................................13804
PIN ASSIGNMENT TABLE................................................................................................................13806
System Components...................................................................................................................13806
Control Unit........................................................................................................................13806
Actuator............................................................................................................................13806
Adjustable Damping Force Shock Absorber.............................................................................................13806
Warning Lamp........................................................................................................................13806
Vertical G-Sensor...................................................................................................................13807
Lateral G-Sensor....................................................................................................................13807
Acronyms and Abbreviations..........................................................................................................13807
General Diagnosis.......................................................................................................................13807
General Information.................................................................................................................13807
Service Precautions.................................................................................................................13807
Computer System Service Precautions.................................................................................................13807
General Service Precautions.........................................................................................................13807
Parts Handling......................................................................................................................13807
FLASHING CODES......................................................................................................................13808
CLEAR DTC...........................................................................................................................13809
INTERMITTENT CONDITIONS.............................................................................................................13810
BULB CHECK..........................................................................................................................13810
DTC CHECK...........................................................................................................................13810
Basic Diagnosis Flow................................................................................................................13811
Circuit Diagram.....................................................................................................................13812
Parts Location......................................................................................................................13815
Connector List......................................................................................................................13816
Diagnostic Trouble Code (DTC)
Identification........................................................................................13818
DTC2 Actuator Coil Over Current.........................................................................................................13819
Circuit Description.................................................................................................................13819
Diagnostic Aids.....................................................................................................................13819
DTC3 Actuator Coil/Position Sensor Open Circuit or Short................................................................................13821
Circuit Description.................................................................................................................13821
Diagnostic Aids.....................................................................................................................13821
DTC4 G-Sensor Open Circuit or Short.....................................................................................................13824
Circuit Description.................................................................................................................13824
Diagnostic Aids.....................................................................................................................13824
DTC5 Vehicle Speed Sensor Open Circuit or Short.........................................................................................13825
Circuit Description.................................................................................................................13825
Diagnostic Aids.....................................................................................................................13825
DTC6 Stop Lamp Switch Open Circuit or Short.............................................................................................13827
Circuit Description.................................................................................................................13827
Diagnostic Aids.....................................................................................................................13827
DTC7 Engine Speed Signal Open Circuit or Short..........................................................................................13829
Circuit Description.................................................................................................................13829
Diagnostic Aids.....................................................................................................................13829
DTC9 Control Unit Abnormality.......................................................................................................13830
Control Unit............................................................................................................................13834
Control Unit and Associated Parts...................................................................................................13834
Removal.................................................................................................................................13835
Installation............................................................................................................................13835
Front Actuator..........................................................................................................................13836
Front Actuator and Associated Parts.................................................................................................13836
Removal.................................................................................................................................13837
View B..............................................................................................................................13837
Inspection and Repair...................................................................................................................13837
Installation............................................................................................................................13837
Rear Shock Absorber.....................................................................................................................13838
Rear Shock Absorber and Associated Parts............................................................................................13838
Removal.................................................................................................................................13839
Inspection and Repair...................................................................................................................13839
Installation............................................................................................................................13839
Sec.4 DRIVELINE/AXLE............................................................................................................................13840
4A1 Differential (Front)....................................................................................................................13840
Service Precaution......................................................................................................................13840
Front Drive Axle........................................................................................................................13841
Diagnosis...............................................................................................................................13841
Pinion Shaft Oil Seal...................................................................................................................13842
Pinion Shaft Oil Seal and Associated Parts..........................................................................................13842
Removal.............................................................................................................................13842
Inspection and Repair...............................................................................................................13843
Installation........................................................................................................................13843
Front Drive Axle Assembly...............................................................................................................13844
Front Drive Axle Assembly and Associated Parts......................................................................................13844
Removal.............................................................................................................................13845
Installation........................................................................................................................13845
Differential Assembly...................................................................................................................13847
Disassembled View...................................................................................................................13847
Disassembly.........................................................................................................................13848
Reassembly..........................................................................................................................13850
Differential Cage Assembly..............................................................................................................13858
Disassembled View...................................................................................................................13858
Disassembly.........................................................................................................................13858
Inspection and Repair...............................................................................................................13859
Reassembly..........................................................................................................................13859
Main Data and Specifications........................................................................................................13861
Special Tools.......................................................................................................................13864
4A2 Differential (Rear).....................................................................................................................13866
Service Precaution......................................................................................................................13866
General Description.....................................................................................................................13867
Diagnosis...............................................................................................................................13868
Axle Housing............................................................................................................................13870
Axle Housing and Associated Parts...................................................................................................13870
Removal.............................................................................................................................13870
Installation........................................................................................................................13872
Axle Shaft, Oil Seal and Bearing........................................................................................................13872
Axle Shaft and Associated Parts.....................................................................................................13872
Removal.............................................................................................................................13873
Inspection..........................................................................................................................13873
Installation........................................................................................................................13873
Pinion Oil Seal.........................................................................................................................13875
Pinion Oil Seal and Associated Parts................................................................................................13875
Removal.............................................................................................................................13875
Inspection and Repair...............................................................................................................13876
Installation........................................................................................................................13876
Differential Assembly...................................................................................................................13878
Disassembled View...................................................................................................................13878
Inspecting the Axle Before Disassembly..............................................................................................13879
Disassembly.........................................................................................................................13879
Inspection and Repair...............................................................................................................13881
Reassembly..........................................................................................................................13881
Side Bearing Preload Adjustment.....................................................................................................13885
Pinion Installation.................................................................................................................13886
Determination of Backlash & Preload Shims...........................................................................................13887
Backlash Adjustment.................................................................................................................13888
Gear Tooth Pattern Check............................................................................................................13888
Adjustments Affecting Tooth Contact.................................................................................................13889
Differential Case Assembly..............................................................................................................13890
Disassembled View...................................................................................................................13890
Disassembly.........................................................................................................................13891
Inspection and Repair...............................................................................................................13891
Reassembly..........................................................................................................................13891
Limited Slip Differential Assembly......................................................................................................13892
Disassembled View...................................................................................................................13892
Disassembly.........................................................................................................................13892
Inspection and Repair...............................................................................................................13894
Reassembly..........................................................................................................................13894
Main Data And Specifications............................................................................................................13896
Special Tools...........................................................................................................................13898
4B DRIVELINE CONTROL SYSTEM................................................................................................................13900
Service Precaution......................................................................................................................13900
Shift On The Fly System.................................................................................................................13901
Outline of Shift on The Fly System......................................................................................................13901
Functions of Indicator Lamp.............................................................................................................13905
Diagnosis...............................................................................................................................13906
Shift On The Fly Electrical Equipment...................................................................................................13916
Axle Shaft Connection and Disconnection.................................................................................................13916
4WD Control Unit........................................................................................................................13919
4WD Control Unit Associated Parts.......................................................................................................13919
Removal.................................................................................................................................13919
Installation............................................................................................................................13920
Shift On The Fly Controller.............................................................................................................13921
Shift On The Fly Controller and Associated Parts........................................................................................13921
Removal.................................................................................................................................13921
Installation............................................................................................................................13921
4C DRIVE SHAFT SYSTEM......................................................................................................................13922
Service Precaution......................................................................................................................13922
General Description.....................................................................................................................13923
Diagnosis...............................................................................................................................13923
Front Hub and Disc (2WD Model)..........................................................................................................13924
Disassembled View...................................................................................................................13924
Disassembly.........................................................................................................................13924
Inspection and Repair...............................................................................................................13925
Reassembly..........................................................................................................................13926
Front Hub and Disc (4WD Model)..........................................................................................................13929
Disassembled View...................................................................................................................13929
Disassembly.........................................................................................................................13929
Inspection and Repair...............................................................................................................13930
Reassembly..........................................................................................................................13931
Front Drive Shaft Joint.................................................................................................................13934
Front Drive Shaft Joints Replace-ment...............................................................................................13934
Front Axle Drive Shaft..................................................................................................................13935
Front Axle Drive Shaft and Associated Parts.........................................................................................13935
Disassembly.........................................................................................................................13936
Inspection And Repair...............................................................................................................13937
Bushing Replacement.................................................................................................................13937
Reassembly..........................................................................................................................13938
Shift On The Fly System.................................................................................................................13940
Shift On The Fly System and Associated Parts........................................................................................13940
Disassembly.........................................................................................................................13941
Inspection And Repair...............................................................................................................13942
Reassembly..........................................................................................................................13944
Main Data and Specifications........................................................................................................13947
Special Tools.......................................................................................................................13949
Propeller Shaft.........................................................................................................................13950
General Description.................................................................................................................13950
Universal Joint.....................................................................................................................13951
Diagnosis of Propeller Shaft and
Universal Joint....................................................................................13952
Front Propeller Shaft...................................................................................................................13953
Front Propeller Shaft and Associated Parts..........................................................................................13953
Removal.............................................................................................................................13953
Installation........................................................................................................................13953
Disassembly.........................................................................................................................13954
Universal Joint Disassembly.........................................................................................................13955
Inspection and Repair...............................................................................................................13956
Universal Joint Reassembly..........................................................................................................13957
Reassembly..........................................................................................................................13958
Main Data and Specifications............................................................................................................13959
Rear Propeller Shaft....................................................................................................................13960
Rear Propeller Shaft and Associated Parts...........................................................................................13960
Removal.............................................................................................................................13960
Installation........................................................................................................................13960
Slip Joint Disassembly..............................................................................................................13961
Universal Joint Disassembly.........................................................................................................13962
Inspection..........................................................................................................................13964
Universal Joint Reassembly..........................................................................................................13965
Slip Joint Reassembly...............................................................................................................13966
Main Data and Specifications........................................................................................................13967
4D TRANSFER CASE...........................................................................................................................13968
Service Precaution......................................................................................................................13968
General Description.....................................................................................................................13969
Transfer Rear Oil Seal..................................................................................................................13971
Transfer Rear Oil Seal and Associated Parts.........................................................................................13971
Removal.............................................................................................................................13971
Installation........................................................................................................................13971
Transfer Case Assembly (A/T)............................................................................................................13973
Transfer Case Assembly (A/T) and Associated Parts...................................................................................13973
Removal.............................................................................................................................13973
Installation........................................................................................................................13975
Transfer Rear Case Assembly (A/T).......................................................................................................13978
Transfer Rear Case Assembly (A/T) and Associated Parts..............................................................................13978
Removal.............................................................................................................................13978
Installation........................................................................................................................13980
Transfer Rear Cover Assembly........................................................................................................13983
Disassembly.........................................................................................................................13983
Inspection and Repair...............................................................................................................13984
Reassembly..........................................................................................................................13984
Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)...........................................................................13986
Disassembled View...................................................................................................................13986
Disassembly.........................................................................................................................13987
Inspection and Repair...............................................................................................................13988
Reassembly..........................................................................................................................13988
Transfer Case Assembly..................................................................................................................13990
Disassembled View...................................................................................................................13990
Disassembly.........................................................................................................................13991
Inspection and Repair...............................................................................................................13994
Reassembly..........................................................................................................................13997
Main Data and Specifications............................................................................................................14004
Special Tools...........................................................................................................................14007
Sec.5 BRAKES....................................................................................................................................14008
5A Brake Control System....................................................................................................................14008
Service Precaution......................................................................................................................14009
General Description.....................................................................................................................14010
Functional Description..............................................................................................................14011
System Components...................................................................................................................14017
Electronic Hydraulic Control Unit (EHCU)............................................................................................14017
ABS Warning Light...................................................................................................................14017
Wheel Speed Sensor..................................................................................................................14017
G-Sensor............................................................................................................................14017
Normal and Anti-lock Braking........................................................................................................14017
Brake Pedal Travel..................................................................................................................14017
Acronyms and Abbreviations..........................................................................................................14017
General Diagnosis.......................................................................................................................14018
General Information.................................................................................................................14018
ABS Service Precautions.............................................................................................................14018
Computer System Service Precautions.................................................................................................14018
General Service Precautions.........................................................................................................14018
Note on Intermittents...............................................................................................................14018
Test Driving ABS Complaint Vehicles.................................................................................................14019
“ABS” Warning Light.................................................................................................................14019
Normal Operation....................................................................................................................14019
Tech 2 Scan Tool....................................................................................................................14020
DATA LIST...........................................................................................................................14023
ACTUATOR TEST.......................................................................................................................14024
Tech 2 Service Bleed................................................................................................................14028
Basic Diagnostic Flow Chart.........................................................................................................14029
Basic Inspection Procedure..........................................................................................................14030
EHCU Connector Pin-out Checks...........................................................................................................14031
Circuit Diagram.....................................................................................................................14032
Connector List......................................................................................................................14035
Part Location.......................................................................................................................14037
Symptom Diagnosis.......................................................................................................................14038
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate......................................................................14038
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................14039
Chart A-2 Uneven Braking Occurs While ABS Works.....................................................................................14039
Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2).......................................................................14039
Chart A-3, TA-3 The Wheels Are Locked...............................................................................................14040
Chart A-4 Brake Pedal Feed Is Abnormal..............................................................................................14040
Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................14041
Diagnostic Trouble Codes................................................................................................................14042
Diagnosis By “ABS” Warning Light Illumination Pattern...................................................................................14044
Diagnostic Trouble Codes (DTCs).....................................................................................................14045
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................14047
Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial communications)).......................................14047
Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial communications))...................................14048
Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications))..................................................14048
Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications)).............................................14048
Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications))..............................................14049
Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications)).................................................14049
Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial communications)), 4WD State Input Sig........14050
Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial communications))............................................14050
Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash out) / C0265, C0266 (Serial communications)).....................................14051
Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial communications))...........................14051
Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial communications))................................14051
5B ANTI-LOCK BRAKE SYSTEM..................................................................................................................14065
Service Precaution......................................................................................................................14065
Electronic Hydraulic Control Unit.......................................................................................................14066
Electronic Hydraulic Control Unit and Associated Parts..............................................................................14066
Removal.............................................................................................................................14066
Disassembled View...................................................................................................................14067
Disassembly.........................................................................................................................14067
Reassembly..........................................................................................................................14067
Installation........................................................................................................................14067
Front Wheel Speed Sensor................................................................................................................14068
Front Wheel Speed Sensor and Associated Parts.......................................................................................14068
Removal.............................................................................................................................14068
Inspection and Repair...............................................................................................................14068
Installation........................................................................................................................14068
Rear Wheel Speed Sensor.................................................................................................................14069
Removal.............................................................................................................................14069
Inspection and Repair...............................................................................................................14069
Installation........................................................................................................................14069
5C POWER-ASSISTED BRAKE SYSTEM.............................................................................................................14070
Service Precaution......................................................................................................................14071
General Description.....................................................................................................................14071
Diagnosis...............................................................................................................................14075
General Diagnosis.......................................................................................................................14076
Hydraulic Brakes........................................................................................................................14079
Filling Master Cylinder Reservoir...................................................................................................14079
Deterioration of Brake Fluid........................................................................................................14079
Leakage of Brake Fluid..............................................................................................................14079
Bleeding Brake Hydraulic System.....................................................................................................14079
Flushing Brake Hydraulic System.....................................................................................................14080
Brake Pipes and Hoses...............................................................................................................14080
Brake Hose Inspection...............................................................................................................14080
Front Caliper Brake Hose................................................................................................................14081
Front Caliper Brake Hose and Associated Parts.......................................................................................14081
Removal.............................................................................................................................14081
Installation........................................................................................................................14081
Rear Axle Brake Hose....................................................................................................................14082
Rear Axle Brake Hose and Associated Parts...........................................................................................14082
Removal.............................................................................................................................14082
Installation........................................................................................................................14082
Brake Pipe..............................................................................................................................14083
Removal.............................................................................................................................14083
Installation........................................................................................................................14083
P & B (Proportioning and Bypass) Valve..................................................................................................14084
P & B (Proportioning and Bypass) Valve Sectional View...............................................................................14084
Removal.............................................................................................................................14084
Installation........................................................................................................................14084
Main Data and Specifications............................................................................................................14085
Brake Pedal.............................................................................................................................14086
Checking Pedal Height...............................................................................................................14086
Checking Pedal Travel...............................................................................................................14086
Brake Pedal and Associated Parts....................................................................................................14087
Removal.............................................................................................................................14087
Installation........................................................................................................................14087
Stoplight Switch........................................................................................................................14088
Parts Location......................................................................................................................14088
Removal.............................................................................................................................14088
Installation........................................................................................................................14088
Main Data and Specifications............................................................................................................14089
Fluid Reservoir Tank....................................................................................................................14090
Fluid Reservoir Tank and Associated Parts...........................................................................................14090
Removal.............................................................................................................................14090
Installation........................................................................................................................14090
Master Cylinder Assembly................................................................................................................14091
Master Cylinder Assembly and Associated Parts.......................................................................................14091
Removal.............................................................................................................................14091
Inspection and Repair...............................................................................................................14091
Installation........................................................................................................................14092
Main Data and Specifications........................................................................................................14093
Special Tools.......................................................................................................................14093
Vacuum Booster Assembly.................................................................................................................14094
Vacuum Booster Assembly and Associated Parts........................................................................................14094
Removal.............................................................................................................................14094
Inspection and Repair...............................................................................................................14094
Installation........................................................................................................................14095
Exterior Components.....................................................................................................................14097
Exterior Components and Associated Parts............................................................................................14097
Removal.............................................................................................................................14097
Inspection and Repair...............................................................................................................14098
Installation........................................................................................................................14098
Vacuum Booster Overhaul.................................................................................................................14098
Vacuum Booster......................................................................................................................14098
Main Data and Specifications............................................................................................................14099
Special Tools...........................................................................................................................14100
Front Disc Brake Pads...................................................................................................................14101
Front Disc Brake Pads Inspection....................................................................................................14101
Front Disc Brake Pads and Associated Parts..........................................................................................14101
Removal.............................................................................................................................14102
Installation........................................................................................................................14102
Front Disc Brake Rotor..................................................................................................................14104
Inspection..........................................................................................................................14104
Replacing Brake Rotors..............................................................................................................14104
Refinishing Brake Rotors............................................................................................................14104
Front Disc Brake Caliper Assembly.......................................................................................................14105
Front Disc Brake Caliper Assembly and Associated Parts..............................................................................14105
Removal.............................................................................................................................14106
Installation........................................................................................................................14106
Front Disc Brake Caliper................................................................................................................14108
Front Disc Brake Caliper Disassembled View..........................................................................................14108
Disassembly.........................................................................................................................14108
Inspection and Repair...............................................................................................................14109
Reassembly..........................................................................................................................14109
Main Data and Specifications........................................................................................................14111
Rear Disc Brake Pads (4×4 Model)........................................................................................................14112
Brake Pads Inspection...............................................................................................................14112
Brake Pads and Associated Parts.....................................................................................................14112
Removal.............................................................................................................................14113
Installation........................................................................................................................14113
Rear Disc Brake Rotor (4×4 Model).......................................................................................................14115
Inspection..........................................................................................................................14115
Replacing Brake Rotors..............................................................................................................14115
Refinishing Brake Rotors............................................................................................................14115
Rear Drum (In Disc) Inside Diameter
Check...........................................................................................14116
Rear Disc Brake Caliper Assembly (4×4 Model)............................................................................................14117
Rear Disc Brake Caliper Assembly and Associated Parts...............................................................................14117
Removal.............................................................................................................................14117
Installation........................................................................................................................14118
Rear Disc Brake Caliper (4×4 Model).....................................................................................................14119
Rear Disc Brake Caliper Disassembled View...........................................................................................14119
Disassembly.........................................................................................................................14120
Inspection and Repair...............................................................................................................14120
Reassembly..........................................................................................................................14120
Main Data and Specifications (4×4 Model)............................................................................................14122
Brake Lining............................................................................................................................14123
Brake Lining and Associated Parts...................................................................................................14123
Removal.............................................................................................................................14123
Brake Lining Inspection.............................................................................................................14124
Installation........................................................................................................................14124
Drum Brake Adjustment (4×2 Model)...................................................................................................14125
Servicing The Brake Drum............................................................................................................14125
Wheel Cylinder Assembly (4×2 Model).....................................................................................................14126
Wheel Cylinder Assembly and Associated Parts........................................................................................14126
Removal.............................................................................................................................14126
Installation........................................................................................................................14126
Disassembled View...................................................................................................................14127
Disassembly.........................................................................................................................14127
Inspection and Repair...............................................................................................................14127
Reassembly..........................................................................................................................14127
Main Data and Specifications........................................................................................................14129
5D1 PARKING BRAKE SYSTEM (4×4 Model)........................................................................................................14130
Service Precaution......................................................................................................................14130
General Description.....................................................................................................................14130
Operation...............................................................................................................................14131
Parking Brake Lever and Front Cable.....................................................................................................14132
Parking Brake Lever Assembly and Associated Parts...................................................................................14132
Removal.............................................................................................................................14132
Installation........................................................................................................................14132
Parking Brake Rear Cable................................................................................................................14133
Parking Brake Rear Cable and Associated Parts.......................................................................................14133
Removal.............................................................................................................................14134
Installation........................................................................................................................14134
Inspection and Repair...............................................................................................................14135
Parking Brake Adjustment................................................................................................................14135
Main Data and Specifications............................................................................................................14136
5D2 PARKING BRAKE SYSTEM (4×2 Model)........................................................................................................14137
Service Precaution......................................................................................................................14137
General Description.....................................................................................................................14137
Parking Brake Lever.....................................................................................................................14138
Parking Brake Lever Assembly and Associated Parts...................................................................................14138
Removal.............................................................................................................................14138
Installation........................................................................................................................14138
Parking Brake Rear Cable................................................................................................................14139
Parking Brake Rear Cable and Associated Parts.......................................................................................14139
Removal.............................................................................................................................14140
Installation........................................................................................................................14140
Parking Brake Adjustment................................................................................................................14140
Main Data and Specifications............................................................................................................14141
Sec.6 ENGINE....................................................................................................................................14142
Y22SE 2.2L ENGINE..........................................................................................................................14142
6A ENGINE MECHANICAL...................................................................................................................14142
Service Precaution..................................................................................................................14143
General Description.................................................................................................................14143
Engine Diagnosis....................................................................................................................14144
Cylinder Head Cover.................................................................................................................14157
Cylinder Head Cover and Associated Parts........................................................................................14157
Removal.........................................................................................................................14157
Installation....................................................................................................................14158
Exhaust Manifold....................................................................................................................14160
Removal.........................................................................................................................14160
Installation....................................................................................................................14160
Crankshaft Pulley...................................................................................................................14161
Removal.........................................................................................................................14161
Installation....................................................................................................................14161
Intake Manifold.....................................................................................................................14162
Removal.........................................................................................................................14162
Installation....................................................................................................................14163
Cylinder Head Assembly..............................................................................................................14165
Removal.........................................................................................................................14165
Installation....................................................................................................................14167
Timing Belt.........................................................................................................................14170
Removal.........................................................................................................................14170
Installation....................................................................................................................14170
Camshaft............................................................................................................................14176
Camshaft and Associated Parts...................................................................................................14176
Removal.........................................................................................................................14176
Installation....................................................................................................................14177
Engine Assembly.....................................................................................................................14180
Removal.........................................................................................................................14180
Installation....................................................................................................................14182
Cylinder Head.......................................................................................................................14184
Cylinder Head and Associated Parts..............................................................................................14184
Disassembly.....................................................................................................................14184
Inspection and Repair...........................................................................................................14185
Reassembly......................................................................................................................14186
Valve Spring, Valve, Valve Guide....................................................................................................14187
Valve Spring, Valve, Valve Guide and Associated Parts...........................................................................14187
Disassembly.....................................................................................................................14188
Inspection and Repair...........................................................................................................14188
Reassembly......................................................................................................................14189
Crankshaft..........................................................................................................................14190
Crankshaft and Associated Parts.................................................................................................14190
Disassembly.....................................................................................................................14190
Inspection and Repair for Bearing...............................................................................................14191
Inspection and Repair for Crankshaft............................................................................................14192
Reassembly......................................................................................................................14193
Piston and Connecting Rod...........................................................................................................14196
Piston, Connecting Rod and Associate Parts......................................................................................14196
Disassembly.....................................................................................................................14196
Inspection and Repair...........................................................................................................14197
Reassembly......................................................................................................................14199
Cylinder Block......................................................................................................................14201
Cylinder Block and Associated Parts.............................................................................................14201
Disassembly.....................................................................................................................14201
Inspection and Repair...........................................................................................................14202
Reassembly......................................................................................................................14202
Balance Unit Assembly...............................................................................................................14204
Balance Unit Assembly and Associated Parts......................................................................................14204
Disassembly.....................................................................................................................14204
Adjustment......................................................................................................................14205
Reassembly......................................................................................................................14207
Main Data and Specifications........................................................................................................14208
Special Tools.......................................................................................................................14214
6B ENGINE COOLING......................................................................................................................14215
Service Precaution..................................................................................................................14215
General Description.................................................................................................................14216
Diagnosis...........................................................................................................................14218
Draining and Refilling Cooling......................................................................................................14218
Water Pump..........................................................................................................................14219
Water Pump and Associated Parts.................................................................................................14219
Removal.........................................................................................................................14219
Inspection......................................................................................................................14219
Installation....................................................................................................................14219
Thermostat..........................................................................................................................14220
Removal.........................................................................................................................14220
Inspection......................................................................................................................14220
Installation....................................................................................................................14220
Radiator............................................................................................................................14221
Radiator and Associated Parts...................................................................................................14221
Removal.........................................................................................................................14222
Inspection......................................................................................................................14223
Installation....................................................................................................................14224
Main Data and Specifications........................................................................................................14225
Special Tool........................................................................................................................14226
6C ENGINE FUEL.........................................................................................................................14227
Service Precaution..................................................................................................................14227
General Description.................................................................................................................14228
Fuel Metering.......................................................................................................................14229
Fuel Filter.........................................................................................................................14230
Fuel Filter and Associated Parts................................................................................................14230
Removal.........................................................................................................................14230
Inspection......................................................................................................................14231
Installation....................................................................................................................14231
Inspection......................................................................................................................14231
In–Tank Fuel Filter.............................................................................................................14231
Fuel Pump Flow Test.............................................................................................................14231
Pressure test...................................................................................................................14231
Fuel Pump...........................................................................................................................14232
Fuel Pump and Associated Parts..................................................................................................14232
Removal.........................................................................................................................14232
Installation....................................................................................................................14233
Fuel Tube / Quick – Connector Fittings..............................................................................................14233
Precautions.....................................................................................................................14233
Cautions During Work............................................................................................................14233
Removal.........................................................................................................................14233
Reuse of Quick–Connector........................................................................................................14234
Assembling Advice...............................................................................................................14234
Fuel Pump Relay.....................................................................................................................14234
General Description.............................................................................................................14234
Fuel Tank...........................................................................................................................14235
Fuel Tank and Associated Parts..................................................................................................14235
Removal.........................................................................................................................14235
Installation....................................................................................................................14235
Fuel Gage Unit......................................................................................................................14236
Removal and Installation........................................................................................................14236
Fuel Filler Cap.....................................................................................................................14236
General Description.............................................................................................................14236
Inspection......................................................................................................................14236
Main Data and Specifications........................................................................................................14237
Torque Specification............................................................................................................14237
Special Tool........................................................................................................................14237
6D1 ENGINE ELECTRICAL...................................................................................................................14238
Service Precaution..................................................................................................................14238
Battery.............................................................................................................................14239
General Description.................................................................................................................14239
Diagnosis...........................................................................................................................14239
Battery Charging................................................................................................................14240
Jump Starting...................................................................................................................14240
Battery Removal.................................................................................................................14241
Battery Installation............................................................................................................14241
Main Data and Specifications....................................................................................................14242
6D2 IGNITION SYSTEM.....................................................................................................................14243
Service Precaution..................................................................................................................14243
General Description.................................................................................................................14244
Diagnosis...........................................................................................................................14244
Ignition Module.....................................................................................................................14245
Removal.........................................................................................................................14245
Installation....................................................................................................................14245
Spark Plug..........................................................................................................................14246
Removal.........................................................................................................................14246
Inspection and Repair...........................................................................................................14246
Installation....................................................................................................................14246
Crankshaft Position Sensor..........................................................................................................14247
Removal.........................................................................................................................14247
Installation....................................................................................................................14247
Main Data and Specifications........................................................................................................14248
6D3 STARTING AND CHARGING SYSTEM........................................................................................................14249
Service Precaution..................................................................................................................14249
Starting System.....................................................................................................................14250
General Description.................................................................................................................14250
Diagnosis...........................................................................................................................14250
Starter.............................................................................................................................14251
Removal.........................................................................................................................14251
Installation....................................................................................................................14251
Disassembled View...............................................................................................................14252
Inspection and Repair...........................................................................................................14253
Characteristic Test.............................................................................................................14254
Charging System.....................................................................................................................14255
General Description.............................................................................................................14255
General On–Vehicle Inspection...................................................................................................14255
Generator...........................................................................................................................14256
Removal.........................................................................................................................14256
Inspection......................................................................................................................14256
Installation....................................................................................................................14257
Disassembled View...............................................................................................................14258
Disassembly.....................................................................................................................14259
Inspection and Repair...........................................................................................................14260
Reassembly......................................................................................................................14261
Main Data and Specifications....................................................................................................14262
6E1 RODEO 2.2L ENGINE DRIVEABILITY AND EMISSIONS........................................................................................14263
SPECIFICATIONS......................................................................................................................14268
DIAGRAMS AND SCHEMATICS.............................................................................................................14269
PCM PINOUTS.........................................................................................................................14282
COMPONENT LOCATOR...............................................................................................................14288
Undercarriage Component Locator Table...........................................................................................14290
Fuse And Relay Panel (Underhood Electrical Center)..............................................................................14291
DIAGNOSIS Strategy-Based Diagnostics................................................................................................14292
Strategy-Based Diagnostics......................................................................................................14292
DTC Stored......................................................................................................................14292
No DTC..........................................................................................................................14292
No Matching Symptom.............................................................................................................14292
Intermittents...................................................................................................................14292
No Trouble Found................................................................................................................14292
Verifying Vehicle Repair........................................................................................................14292
GENERAL SERVICE INFORMATION.........................................................................................................14293
OBD II Serviceability Issues....................................................................................................14293
Emissions Control Information Label.............................................................................................14293
Maintenance Schedule............................................................................................................14294
Visual/Physical Engine Compartment Inspection...................................................................................14294
Basic Knowledge Of Tools Required...............................................................................................14294
SERIAL DATA COMMUNICATIONS..........................................................................................................14294
Class II Serial Data Communications.............................................................................................14294
ON-BOARDDIAGNOSTIC (OBD II).........................................................................................................14294
O-Board Diagnostic Tests........................................................................................................14294
Comprehensive Component Monitor Diagnostic Operation............................................................................14294
System Status And Drive Cycle For Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...............................14295
Common OBD II Terms.............................................................................................................14295
The Diagnostic Executive........................................................................................................14296
DTC Types.......................................................................................................................14297
Decimal/Binary/Hexadecimal Conversions..........................................................................................14298
Verifying Vehicle Repair........................................................................................................14298
Reading Diagnostic Trouble Codes Using A Tech 2 Scan Tool.......................................................................14298
Tech 2 Features.................................................................................................................14300
Getting Started.................................................................................................................14300
Operating Procedure (Example)...................................................................................................14301
DTC Modes.......................................................................................................................14302
DTC Information Mode............................................................................................................14302
Miscellaneous Test..............................................................................................................14303
Lamps Test......................................................................................................................14303
Relays Test.....................................................................................................................14304
EVAP Test.......................................................................................................................14306
Idle Air Control System Test....................................................................................................14307
Fuel System Test................................................................................................................14309
EGR Control Test................................................................................................................14310
Injector Balance Test...........................................................................................................14311
Plotting Snapshot Graph.............................................................................................................14312
System Check at Tech 2..............................................................................................................14313
General Description.............................................................................................................14313
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)..................................................14317
Flow Chart for Snapshot Replay (Plotting Graph).................................................................................14318
PRIMARY SYSTE-BASED DIAGNOSTICS.....................................................................................................14319
Primary System-Based Diagnostics................................................................................................14319
Fuel Control Heated Oxygen Sensors..............................................................................................14319
HO2S Heater.....................................................................................................................14319
Catalyst Monitor Heated Oxygen Sensors And Diagnostic Operation.................................................................14319
MISFIRE MONITOR following conditions: DIAGNOSTIC OPERATION..........................................................................14320
Misfire Monitor Diagnostic Operation............................................................................................14320
Misfire Counters................................................................................................................14320
FUEL TRIM SYSTEM MONITOR DIAGNOSTIC OPERATION.......................................................................................14321
Fuel Trim System Monitor Diagnostic Operation...................................................................................14321
Fuel Trim Cell Diagnostic Weights...............................................................................................14321
ON‐BOARD DIAGNOSTIC (OBD II) SYSTEM CHECK...........................................................................................14322
A/C CLUTCH CONTROL CIRCUIT DIAGNOSIS................................................................................................14325
ELECTRONIC IGNITION SYSTEM DIAGNOSIS................................................................................................14328
EVAP CANISTER PURGE SOLENOID........................................................................................................14328
VISUAL CHECK OF THE EVAPORATIVE EMISSION CANISTER...................................................................................14328
IDLE AIR CONTROL (IAC) VALVE........................................................................................................14328
FUEL SYSTEM PRESSURE TEST...........................................................................................................14328
FUEL METERING SYSTEM CHECK..........................................................................................................14329
FUEL INJECTOR COIL TEST PROCEDURE AND FUEL INJECTOR BALANCE TEST PROCEDURE..........................................................14329
POWERTRAIN CONTROL MODULE (PCM) DIAGNOSIS...........................................................................................14334
MULTIPLE PCM INFORMATION SENSOR DTCs SET............................................................................................14335
EXHAUST GAS RECIRCULATION (EGR) DIAGNOSIS...........................................................................................14338
ENGINE Tech 2 DATA DEFINITIONS AND RANGES...........................................................................................14338
TYPICAL SCAN DATA VALUES............................................................................................................14341
NO MALFUNCTION INDICATOR LAMP (MIL).................................................................................................14345
MALFUNCTION INDICATOR LAMP (MIL) ON STEADY..........................................................................................14348
ENGINE CRANKS BUT WILL NOT RUN......................................................................................................14350
FUEL SYSTEM ELECTRICAL TEST.........................................................................................................14356
FUEL SYSTEM DIAGNOSIS...............................................................................................................14359
IDLE AIR CONTROL (IAC) SYSTEM CHECK.................................................................................................14364
EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK........................................................................................14367
MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK.......................................................................................14369
EVAPORATIVE (EVAP) EMISSIONS CANISTER PURGE VALVE SOLENOID CHECK....................................................................14371
Upshift Lamp System Check (Manual Transmission Only)................................................................................14374
PCM DIAGNOSTIC TROUBLE CODES........................................................................................................14377
(DTC) P0106 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT/RANGE PERFORMANCE PROBLEM......................................................14380
(DTC) P0107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT LOW INPUT...............................................................14383
(DTC) P0108 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT HIGH INPUT.....................................................................14386
(DTC) P0112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW INPUT...................................................................14389
(DTC) P0113 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH INPUT..................................................................14392
(DTC) P0117 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT LOW INPUT...............................................................14395
(DTC) P0118 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT HIGH INPUT..............................................................14398
(DTC) P0121 THROTTLE POSITION (TP) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM.........................................................14401
(DTC) P0122 THROTTLE POSITION (TP) SENSOR CIRCUITLOW INPUT..........................................................................14404
(DTC) P0123 THROTTLE POSITION (TP) SENSOR CIRCUIT HIGH INPUT........................................................................14407
(DTC) P0125 INSUFFICIENT COOLANT TEM-PERATURE FOR CLOSED LOOP FUEL CONTROL..........................................................14410
(DTC) P0128 Thermostat Insufficient temperrature for Stable Opreation...............................................................14413
(DTC) P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1).........................................................................14415
(DTC) P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)........................................................................14418
(DTC) P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1).......................................................................14421
(DTC) P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)................................................................14424
(DTC) P0135 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 1)..................................................................14427
(DTC) P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2).........................................................................14430
(DTC) P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)........................................................................14433
(DTC) P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 2)................................................................14436
(DTC) P0141 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 2)..................................................................14439
(DTC) P0171 SYSTEM TOO LEAN (BANK 1)................................................................................................14442
(DTC) P0172 SYSTEM TOO RICH (BANK 1)................................................................................................14446
(DTC) P0201 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 1...............................................................................14450
(DTC) P0202 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 2...............................................................................14453
(DTC) P0203 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 3...............................................................................14456
(DTC) P0204 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 4...............................................................................14459
(DTC) P0300 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................14462
(DTC) P0301 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................14466
(DTC) P0302 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................14470
(DTC) P0303 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................14474
(DTC) P0304 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................14478
(DTC) P0325 KNOCK SENSOR (KS) CIRCUIT MALFUNCTION...................................................................................14482
(DTC) P0327 KNOCK SENSOR (KS) CIRCUIT LOW INPUT.....................................................................................14485
(DTC) P0336 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT RANGE/PERFORMANCE..............................................................14488
(DTC) P0337 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT LOW INPUT......................................................................14490
(DTC) P0341 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT RANGE/PERFORMANCE................................................................14493
(DTC) P0342 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT LOW INPUT........................................................................14496
(DTC) P0351 IGNITION COIL ”A” PRIMARY/ SECONDARY CIRCUIT MALFUNCTION................................................................14499
(DTC) P0352 IGNITION COIL ”B” PRIMARY/ SECONDARY CIRCUIT MALFUNCTION................................................................14501
(DTC) P0401 EXHAUST GAS RECIRCULATION (EGR) FLOW INSUFFICIENT DETECTED..............................................................14503
(DTC) P0402 EXHAUST GAS RECIRCULATION (EGR) EXCESSIVE FLOW DETECTED.................................................................14506
(DTC) P0404 EXHAUST GAS RECIRCULATION (EGR) CIRCUIT RANGE/PERFORMANCE...............................................................14508
(DTC) P0405 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT LOW......................................................................14512
(DTC) P0406 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT HIGH.....................................................................14515
(DTC) P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD..............................................................................14519
(DTC) P0440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM MALFUNCTION..................................................................14522
(DTC) P0442 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM SMALL LEAK DETECTED..........................................................14527
(DTC) P0456 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VERY SMALL LEAK DETECTED.....................................................14531
(DTC) P0443 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION......................................14535
(DTC) P0446 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT CONTROL CIRCUIT MALFUNCTION.............................................14538
(DTC) P0449 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT VALVE/SOLENOID CIRCUIT MALFUNCTION......................................14542
(DTC) P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE.............................................................................14545
(DTC) P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT.....................................................................................14547
(DTC) P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT....................................................................................14549
(DTC) P0464 Fuel Level Sensor Noisy Signal..........................................................................................14551
(DTC) P0480 COOLING FAN 1 CONTROL CIRCUIT MALFUNCTION...............................................................................14553
(DTC) P0481 COOLING FAN 2 CONTROL CIRCUIT MALFUNCTION...............................................................................14556
(DTC) P0502 VEHICLE SPEED SENSOR (VSS) CIRCUIT LOW INPUT............................................................................14559
(DTC) P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED.............................................................................14561
(DTC) P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED............................................................................14564
(DTC) P0532 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT LOW INPUT.......................................................................14567
(DTC) P0533 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT HIGH INPUT......................................................................14570
(DTC) P0562 SYSTEM VOLTAGE LOW......................................................................................................14573
(DTC) P0563 SYSTEM VOLTAGE HIGH.....................................................................................................14575
(DTC) P0601 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR..........................................................................14577
(DTC) P1106 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE...............................................14579
(DTC) P1107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE................................................14581
(DTC) P1111 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE...................................................14583
(DTC) P1112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE....................................................14586
(DTC) P1114 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE................................................14588
(DTC) P1115 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE...............................................14590
(DTC) P1121 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE.........................................................14593
(DTC) P1122 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE..........................................................14595
(DTC) P1133 O2 SENSOR INSUFFICIENT SWITCHING (BANK 1 SENSOR 1)......................................................................14597
(DTC) P1134 O2 SENSOR TRANSITION TIME RATIO (BANK 1 SENSOR 1).......................................................................14600
(DTC) P1171 FUEL SYSTEM LEAN DURING ACCELERATION....................................................................................14603
(DTC) P1336 CRANKSHAFT POSITION SENSOR (CKP) SYSTEM VARIATION NOT LEARNED...........................................................14606
(DTC) P1380 ABS ROUGH ROAD SYSTEM FAULT.............................................................................................14609
(DTC) P1381 ABS ROUGH ROAD CLASS 2 SERIAL DATA FAULT................................................................................14611
(DTC) P1404 EXHAUST GAS RECIRCULATION (EGR) CLOSED VALVE............................................................................14614
(DTC) P1441 EVAPORATIVE EMISSION (EVAP) SYSTEM FLOW DURING NO-PURGE.................................................................14617
(DTC) P1546 A/C COMPRESSOR CLUTCH OUTPUT CIRCUIT MALFUNCTION........................................................................14620
(DTC) P1618 Serial Peripheral Interface (SPI) PCM Interprocessor Communication Error................................................14623
(DTC) P1625 PCM Unexpected Reset....................................................................................................14624
(DTC) P1627 PCM A/D CONVERSION MALFUNCTION..........................................................................................14626
(DTC) P1635 5 VOLT REFERENCE VOLTAGE CIRCUIT MALFUNCTION............................................................................14628
SYMPTOM DIAGNOSIS...................................................................................................................14630
DEFAULT MATRIX TABLE................................................................................................................14653
Camshaft Position (CMP) Sensor......................................................................................................14656
Removal Procedure...............................................................................................................14656
Installation Procedure..........................................................................................................14656
Crankshaft Position (CKP) Sensor....................................................................................................14657
Removal Procedure...............................................................................................................14657
Installation Procedure..........................................................................................................14658
EEPROM..............................................................................................................................14659
EEPROM..........................................................................................................................14659
EEPROM Programming..............................................................................................................14659
Engine Coolant Temperature (ECT) Sensor.............................................................................................14659
Removal Procedure...............................................................................................................14659
Installation Procedure..........................................................................................................14660
Heated Oxygen Sensor (HO2S).........................................................................................................14660
Removal Procedure...............................................................................................................14660
Inspection Procedure............................................................................................................14660
Installation Procedure..........................................................................................................14661
Intake Air Temperature (IAT) Sensor.................................................................................................14661
Removal Procedure...............................................................................................................14661
Installation Procedure..........................................................................................................14662
Manifold Absolute Pressure (MAP) Sensor.............................................................................................14662
Removal Procedure...............................................................................................................14662
Installation Procedure..........................................................................................................14662
Malfunction Indicator Lamp (MIL)....................................................................................................14663
Malfunction Indicator Lamp (MIL)................................................................................................14663
Powertrain Control Module (PCM).....................................................................................................14663
Electrostatic Discharge (ESD) Damage............................................................................................14663
Removal Procedure...............................................................................................................14663
Installation Procedure..........................................................................................................14665
Throttle Position (TP) Sensor.......................................................................................................14666
Removal Procedure...............................................................................................................14666
Function Check..................................................................................................................14666
Installation Procedure..........................................................................................................14666
Vehicle Speed Sensor (VSS)..........................................................................................................14667
Removal Procedure...............................................................................................................14667
Inspection Procedure............................................................................................................14667
Installation Procedure..........................................................................................................14667
Air Filter..........................................................................................................................14668
Removal Procedure...............................................................................................................14668
Installation Procedure..........................................................................................................14668
Idle Air Control (IAC) Valve........................................................................................................14669
Removal Procedure...............................................................................................................14669
Cleaning and Inspection Procedure...............................................................................................14669
Measurement Procedure...........................................................................................................14670
Installation Procedure..........................................................................................................14670
Intake Air Duct.....................................................................................................................14670
Removal Procedure...............................................................................................................14670
Installation Procedure..........................................................................................................14671
Knock Sensor........................................................................................................................14672
Removal Procedure...............................................................................................................14672
Installation Procedure..........................................................................................................14672
Oil Pressure Switch.................................................................................................................14673
Removal Procedure...............................................................................................................14673
Installation Procedure..........................................................................................................14673
FUEL METERING SYSTEM Accelerator Cable Assembly.....................................................................................14673
Removal Procedure...............................................................................................................14673
Inspection Procedure............................................................................................................14674
Installation Procedure..........................................................................................................14674
Accelerator Cable Adjustment....................................................................................................14675
Accelerator Pedal Replacement.......................................................................................................14675
Removal Procedure...............................................................................................................14675
Installation Procedure..........................................................................................................14675
Fuel Filler Cap.....................................................................................................................14676
Fuel Filler Cap.....................................................................................................................14676
Inspection Procedure............................................................................................................14676
Fuel Filter.........................................................................................................................14676
Removal Procedure...............................................................................................................14676
Inspection Procedure............................................................................................................14677
Installation Procedure..........................................................................................................14677
Fuel Injectors......................................................................................................................14678
Removal Procedure...............................................................................................................14678
Inspection Procedure............................................................................................................14678
Installation Procedure..........................................................................................................14678
Fuel Pressure Regulator.............................................................................................................14679
Removal Procedure...............................................................................................................14679
Installation Procedure..........................................................................................................14680
Fuel Pressure Relief Procedure..................................................................................................14680
Fuel Pump Assembly..................................................................................................................14681
Removal Procedure...............................................................................................................14681
Inspection Procedure............................................................................................................14682
Installation Procedure..........................................................................................................14682
Fuel Pump Relay.....................................................................................................................14683
Removal Procedure...............................................................................................................14683
Installation Procedure..........................................................................................................14683
Fuel Rail Assembly..................................................................................................................14683
Removal Procedure...............................................................................................................14683
Installation Procedure..........................................................................................................14684
Fuel Tank...........................................................................................................................14685
Removal Procedure...............................................................................................................14685
Installation Procedure..........................................................................................................14685
Throttle body (TB)..................................................................................................................14686
Removal Procedure...............................................................................................................14686
Inspection Procedure............................................................................................................14686
Installation Procedure..........................................................................................................14687
ELECTRONIC IGNITION SYSTEM Ignition Control Module (ICM)............................................................................14688
Removal Procedure...............................................................................................................14688
Installation Procedure..........................................................................................................14688
Ignition Coil.......................................................................................................................14688
Removal Procedure...............................................................................................................14688
Installation Procedure..........................................................................................................14688
Spark Plugs.........................................................................................................................14689
Removal Procedure...............................................................................................................14689
Inspection Procedure............................................................................................................14689
Installation Procedure..........................................................................................................14690
Spark Plug Cables...................................................................................................................14690
Spark Plug Cables...................................................................................................................14690
Inspection Procedure............................................................................................................14690
EMISSIONS Catalytic Converter.......................................................................................................14691
Catalytic Converter.............................................................................................................14691
Air Conditioning Relay..............................................................................................................14691
Removal Procedure...............................................................................................................14691
Installation Procedure..........................................................................................................14691
Ignition Timing Adjustment..........................................................................................................14691
Ignition Timing Adjustment......................................................................................................14691
EVAP Canister Hoses.................................................................................................................14691
EVAP Canister Hoses.............................................................................................................14691
EVAP Canister.......................................................................................................................14691
Removal Procedure...............................................................................................................14691
Inspection Procedure............................................................................................................14691
Installation Procedure..........................................................................................................14691
EVAP Canister Vent Solenoid.........................................................................................................14692
Removal Procedure...............................................................................................................14692
Installation Procedure..........................................................................................................14692
EVAP Canister Purge Valve Solenoid..................................................................................................14692
Removal Procedure...............................................................................................................14692
Installation Procedure..........................................................................................................14693
Linear Exhaust Gas Recirculation (EGR) Valve........................................................................................14693
Removal Procedure...............................................................................................................14693
Inspection Procedure............................................................................................................14693
Installation Procedure..........................................................................................................14694
Wiring and Connectors...............................................................................................................14695
Wiring Harness Service..........................................................................................................14695
PCM Connectors And Terminals........................................................................................................14695
Removal Procedure...............................................................................................................14695
Installation Procedure..........................................................................................................14695
Connectors And Terminals............................................................................................................14695
Connectors And Terminals........................................................................................................14695
Wire Harness Repair: Twisted Shielded Cable.........................................................................................14695
Removal Procedure...............................................................................................................14695
Installation Procedure..........................................................................................................14696
Twisted Leads.......................................................................................................................14696
Removal Procedure...............................................................................................................14696
Installation Procedure..........................................................................................................14696
Weathe-Pack Connector...............................................................................................................14697
Tools Required..................................................................................................................14697
Removal Procedure...............................................................................................................14697
Installation Procedure..........................................................................................................14698
Com-Pack III........................................................................................................................14698
Com-Pack III....................................................................................................................14698
Metri-Pack..........................................................................................................................14699
Tools Required..................................................................................................................14699
Removal Procedure...............................................................................................................14699
Installation Procedure..........................................................................................................14699
GENERAL DESCRIPTION-PCM AND SENSORS.................................................................................................14699
GENERAL DESCRIPTION-AIRINDUCTION....................................................................................................14707
GENERAL DESCRIPTION-FUELMETERING....................................................................................................14707
GENERAL DESCRIPTION-ELECTRONIC IGNITION SYSTEM......................................................................................14710
A/C CLUTCH DIAGNOSIS................................................................................................................14714
GENERAL DESCRIPTION-EVAPORATIVE EMISSION (EVAP)SYSTEM...............................................................................14714
GENERAL DESCRIPTION-EXHAUST GAS RECIRCULATION(EGR) SYSTEM...........................................................................14716
GENERAL DESCRIPTION-POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM.....................................................................14717
SPECIAL TOOLS.......................................................................................................................14718
6F ENGINE EXHAUST......................................................................................................................14720
Service Precaution..................................................................................................................14720
General Description.................................................................................................................14721
Front Exhaust Pipe..................................................................................................................14722
Front Exhaust Pipe and Associated Parts.........................................................................................14722
Removal.........................................................................................................................14722
Installation....................................................................................................................14722
Exhaust Silencer....................................................................................................................14723
Exhaust Silencer and Associated Parts...........................................................................................14723
Removal.........................................................................................................................14723
Installation....................................................................................................................14723
Rear Exhaust pipe...................................................................................................................14724
Rear Exhaust pipe and Associated Parts..........................................................................................14724
Removal.........................................................................................................................14724
Installation....................................................................................................................14724
Main Data and Specifications........................................................................................................14725
6G ENGINE LUBRICATION..................................................................................................................14726
Service Precaution..................................................................................................................14726
General Description.................................................................................................................14727
Oil Pump............................................................................................................................14728
Oil Pump and Associated Parts...................................................................................................14728
Disassembly.....................................................................................................................14729
Inspection and Repair...........................................................................................................14729
Reassembly......................................................................................................................14729
6H ENGINE SPEED CONTROL SYSTEM.........................................................................................................14730
Service Precaution..................................................................................................................14730
Accelerator Pedal Control Cable.....................................................................................................14731
Removal.........................................................................................................................14731
Inspection......................................................................................................................14731
Installation....................................................................................................................14731
Adjustment......................................................................................................................14731
Accelerator Pedal...................................................................................................................14732
Accelerator Pedal and Associated Parts..........................................................................................14732
Removal.........................................................................................................................14732
Installation....................................................................................................................14732
6J INDUCTION...........................................................................................................................14733
Service Precaution..................................................................................................................14733
Air Cleaner Filter..................................................................................................................14734
Removal.........................................................................................................................14734
Inspection......................................................................................................................14734
Installation....................................................................................................................14734
6VD1 3.2L ENGINE..........................................................................................................................14735
6A ENGINE MECHANICAL...................................................................................................................14735
Service Precaution..................................................................................................................14736
General Description.................................................................................................................14737
Engine Diagnosis....................................................................................................................14738
Cylinder Head Cover LH..............................................................................................................14753
Removal.........................................................................................................................14753
Installation....................................................................................................................14754
Cylinder Head Cover RH..............................................................................................................14755
Removal.........................................................................................................................14755
Installation....................................................................................................................14755
Common Chamber......................................................................................................................14756
Removal.........................................................................................................................14756
Installation....................................................................................................................14756
Exhaust Manifold LH.................................................................................................................14758
Removal.........................................................................................................................14758
Installation....................................................................................................................14758
Exhaust Manifold RH.................................................................................................................14759
Removal.........................................................................................................................14759
Installation....................................................................................................................14759
Crankshaft Pulley...................................................................................................................14760
Removal.........................................................................................................................14760
Installation....................................................................................................................14760
Timing Belt.........................................................................................................................14761
Removal.........................................................................................................................14761
Installation....................................................................................................................14762
Camshaft............................................................................................................................14765
Removal.........................................................................................................................14765
Installation....................................................................................................................14766
Cylinder Head.......................................................................................................................14768
Removal.........................................................................................................................14768
Installation....................................................................................................................14768
Valve Stem Oil Controller , Valve Spring and Valve Guide............................................................................14770
Removal.........................................................................................................................14770
Installation....................................................................................................................14770
Piston, Piston Ring and Connecting Rod..............................................................................................14771
Removal.........................................................................................................................14771
Installation....................................................................................................................14772
Crankshaft and Main Bearings........................................................................................................14773
Removal.........................................................................................................................14773
Installation....................................................................................................................14774
Rear Oil Seal.......................................................................................................................14778
Removal.........................................................................................................................14778
Installation....................................................................................................................14778
Engine Assembly.....................................................................................................................14779
Removal.........................................................................................................................14779
Installation....................................................................................................................14780
Cylinder Head.......................................................................................................................14782
Cylinder Head and Associated Parts..............................................................................................14782
Disassembly.....................................................................................................................14782
Clean...........................................................................................................................14783
Inspection and Repair...........................................................................................................14783
Reassembly......................................................................................................................14784
Valve Spring, Oil Controller, Valve, Valve Guide....................................................................................14786
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts...........................................................14786
Disassembly.....................................................................................................................14786
Inspection and Repair...........................................................................................................14787
Reassembly......................................................................................................................14790
Camshaft............................................................................................................................14793
Camshaft and Associated Parts...................................................................................................14793
Disassembly.....................................................................................................................14793
Inspection and Repair...........................................................................................................14794
Reassembly......................................................................................................................14796
Crankshaft..........................................................................................................................14799
Crankshaft and Associated Parts.................................................................................................14799
Disassembly.....................................................................................................................14799
Inspection and Repair for Bearings..............................................................................................14800
Inspection and Repair for Crankshaft............................................................................................14802
Reassembly......................................................................................................................14803
Piston and Connecting Rod...........................................................................................................14807
Piston, Connecting Rod and Associate Parts......................................................................................14807
Disassembly.....................................................................................................................14807
Inspection and Repair...........................................................................................................14808
Reassembly......................................................................................................................14812
Cylinder Block......................................................................................................................14814
Cylinder Block and Associated Parts.............................................................................................14814
Disassembly.....................................................................................................................14814
Inspection and Repair...........................................................................................................14815
Reassembly......................................................................................................................14816
Main Data and Specification.........................................................................................................14819
Special Tool........................................................................................................................14825
6B ENGINE COOLING......................................................................................................................14827
Service Precaution..................................................................................................................14827
General Description.................................................................................................................14828
Diagnosis...........................................................................................................................14830
Draining and Refilling Cooling System...............................................................................................14831
Water Pump..........................................................................................................................14832
Water Pump and Associated Parts.................................................................................................14832
Removal.........................................................................................................................14832
Inspection......................................................................................................................14832
Installation....................................................................................................................14832
Thermostat..........................................................................................................................14833
Thermostat and Associated Parts.................................................................................................14833
Removal.........................................................................................................................14833
Inspection......................................................................................................................14833
Installation....................................................................................................................14833
Radiator............................................................................................................................14834
Radiator and Associated Parts...................................................................................................14834
Removal.........................................................................................................................14834
Inspection......................................................................................................................14835
Installation....................................................................................................................14836
Drive Belt and Cooling Fan..........................................................................................................14837
Drive Belt and Associated Parts.................................................................................................14837
Removal.........................................................................................................................14837
Inspection......................................................................................................................14837
Installation....................................................................................................................14837
Main Data and Specifications........................................................................................................14838
Special Tool........................................................................................................................14839
6C ENGINE FUEL FOR LONG WHEEL BASE.....................................................................................................14840
Service Precaution..................................................................................................................14840
General Description.................................................................................................................14841
Fuel Metering.......................................................................................................................14842
Fuel Filter.........................................................................................................................14843
Removal.........................................................................................................................14843
Inspection......................................................................................................................14843
Installation....................................................................................................................14844
Inspection......................................................................................................................14844
In–Tank Fuel Filter.............................................................................................................14844
Fuel Pump Flow Test.............................................................................................................14844
Fuel Pump...........................................................................................................................14845
Fuel Pump and Associated Parts..................................................................................................14845
Removal.........................................................................................................................14845
Installation....................................................................................................................14846
Fuel Tube / Quick – Connector Fittings..............................................................................................14846
Precautions.....................................................................................................................14846
Cautions During Work............................................................................................................14846
Removal.........................................................................................................................14846
Reuse of Quick–Connector........................................................................................................14847
Assembling Advice...............................................................................................................14847
Fuel Pump Relay.....................................................................................................................14848
General Description.............................................................................................................14848
Fuel Tank...........................................................................................................................14848
Fuel Tank and Associated Parts..................................................................................................14848
Removal.........................................................................................................................14848
Installation....................................................................................................................14849
Fuel Gauge Unit.....................................................................................................................14849
Removal and Installation........................................................................................................14849
Fuel Filler Cap.....................................................................................................................14849
General Description.............................................................................................................14849
Inspection......................................................................................................................14849
Main Data and Specifications........................................................................................................14850
Special Tool....................................................................................................................14850
6D1 ENGINE ELECTRICAL...................................................................................................................14851
Service Precaution..................................................................................................................14851
Battery.............................................................................................................................14852
General Description.................................................................................................................14852
Diagnosis...........................................................................................................................14852
Battery Charging....................................................................................................................14853
Jump Starting.......................................................................................................................14853
Battery Removal.....................................................................................................................14854
Battery Installation................................................................................................................14854
Main Data and Specifications........................................................................................................14855
6D2 IGNITION SYSTEM.....................................................................................................................14856
Service Precaution..................................................................................................................14856
General Description.................................................................................................................14857
Diagnosis...........................................................................................................................14857
Ignition Coil.......................................................................................................................14858
Removal.........................................................................................................................14858
Inspection and Repair...........................................................................................................14858
Installation....................................................................................................................14858
Spark Plug..........................................................................................................................14860
Removal.........................................................................................................................14860
Inspection and Repair...........................................................................................................14860
Installation....................................................................................................................14860
Crankshaft Position Sensor..........................................................................................................14861
Removal.........................................................................................................................14861
Installation....................................................................................................................14861
Main Data and Specifications........................................................................................................14862
6D3 STARTING AND CHARGING SYSTEM........................................................................................................14863
Service Precaution..................................................................................................................14863
Starting System.....................................................................................................................14864
General Description.................................................................................................................14864
Diagnosis...........................................................................................................................14866
Starter.............................................................................................................................14867
Removal.........................................................................................................................14867
Installation....................................................................................................................14867
Disassembled View...............................................................................................................14869
Disassembly.....................................................................................................................14870
Inspection and Repair...........................................................................................................14872
Reassembly......................................................................................................................14875
Main Data and Specifications....................................................................................................14876
Charging System.....................................................................................................................14879
General Description.............................................................................................................14879
General On–Vehicle Inspection...................................................................................................14879
Generator...........................................................................................................................14880
Removal.........................................................................................................................14880
Inspection......................................................................................................................14880
Installation....................................................................................................................14881
Disassembled View...............................................................................................................14881
Disassembly.....................................................................................................................14882
Inspection and Repair...........................................................................................................14883
Reassembly......................................................................................................................14885
Bench Test......................................................................................................................14886
Main Data and Specifications........................................................................................................14887
6E2 RODEO 3.2L ENGINE DRIVEABILITY AND EMISSIONS........................................................................................14888
Specifications......................................................................................................................14893
Tightening Specifications.......................................................................................................14893
Diagrams and Schematics.............................................................................................................14894
PCM Wiring Diagram (1 of 7).....................................................................................................14894
PCM Wiring Diagram (2 of 7).....................................................................................................14895
PCM Wiring Diagram (3 of 7).....................................................................................................14896
PCM Wiring Diagram (4 of 7).....................................................................................................14897
PCM Wiring Diagram (5 of 7).....................................................................................................14898
PCM Wiring Diagram (6 of 7).....................................................................................................14899
PCM Wiring Diagram (7 of 7).....................................................................................................14900
PCM Pinouts.........................................................................................................................14901
PCM Pinout Table, 80-Way Blue Connector – Row “F1 ~ 20”.........................................................................14901
PCM Pinout Table, 80-Way Blue Connector – Row “F20 ~ 40”........................................................................14902
PCM Pinout Table, 80-Way Blue Connector – Row “F41 ~ 60”........................................................................14903
PCM Pinout Table, 80-Way Blue Connector – Row “F61 ~ 80”........................................................................14904
PCM Pinout Table, 80-Way Red Connector – Row “S1 ~ 20”..........................................................................14906
PCM Pinout Table, 80-Way Red Connector – Row “S21 ~ 40”.........................................................................14908
PCM Pinout Table, 80-Way Red Connector – Row “S41 ~ 60”.........................................................................14910
PCM Pinout Table, 80-Way Red Connector – Row “S61 ~ 80”.........................................................................14912
Component Locators..............................................................................................................14914
Undercarriage Component Locator.................................................................................................14916
Fuse and Relay Panel (Underhood Electrical Center)..............................................................................14917
Sensors and Miscellaneous Component Locators....................................................................................14918
Diagnosis...........................................................................................................................14920
Strategy-Based Diagnostics......................................................................................................14920
DTC Stored......................................................................................................................14920
No DTC..........................................................................................................................14920
No Matching Symptom.............................................................................................................14920
Intermittents...................................................................................................................14920
No Trouble Found................................................................................................................14920
Verifying Vehicle Repair........................................................................................................14920
General Service Information.........................................................................................................14920
OBD II Serviceablity Issues.....................................................................................................14920
Emissions Control Information Label.............................................................................................14921
Visual / Physical Engine Compartment Inspection.................................................................................14921
Basic Knowledge of Tools Required...............................................................................................14922
Serial Data Communications..........................................................................................................14922
Class II Serial Data Communications.............................................................................................14922
On-Board Diagnostic (OBD II)........................................................................................................14922
On-Board Diagnostic Tests.......................................................................................................14922
Comprehensive Component Monitor Diagnostic Operation............................................................................14922
System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...............................14923
Common OBD II Terms.............................................................................................................14923
The Diagnostic Executive........................................................................................................14923
DTC Types.......................................................................................................................14924
Decimal/Binary/Hexadecimal Conversions..........................................................................................14926
Verifying Vehicle Repair........................................................................................................14926
Reading Diagnostic Trouble Codes Using
The Tech 2 Scan Tool.....................................................................14926
Tech 2..........................................................................................................................14927
Tech 2 Features.................................................................................................................14928
Getting Started.................................................................................................................14928
Operating Procedure (For Example)...............................................................................................14929
DTC Modes.......................................................................................................................14930
DTC Information Mode............................................................................................................14930
Miscellaneous Test..............................................................................................................14931
Lamps Test......................................................................................................................14931
Relays Test.....................................................................................................................14933
EVAP Test.......................................................................................................................14934
Fuel System Test................................................................................................................14935
Instruments Test................................................................................................................14937
EGR Control Test................................................................................................................14939
Variable Intake Manifold Solenoid Test..........................................................................................14939
Injector Balance Test...........................................................................................................14941
Plotting Snapshot Graph.............................................................................................................14941
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)..................................................14942
Flow Chart for Snapshot Replay (Plotting Graph).................................................................................14943
Primary System-Based Diagnostic.....................................................................................................14944
Primary System-Based Diagnostic.................................................................................................14944
Fuel Control Heated Oxygen Sensor...............................................................................................14944
HO2S Heater.....................................................................................................................14944
Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation.................................................................14944
Evaporative Emission (EVAP) Purge System Vacuum Switch..........................................................................14945
Misfire Monitor Diagnostic Operation................................................................................................14945
Misfire Monitor Diagnostic Operation............................................................................................14945
Misfire Counters................................................................................................................14946
Fuel Trim System Monitor Diagnostic Operation.......................................................................................14946
Fuel Trim System Monitor Diagnostic Operation...................................................................................14946
Fuel Trim Cell Diagnostic Weights...............................................................................................14946
On-Board Diagnostic (OBD II) System Check...........................................................................................14947
A/C Clutch Control Circuit Diagnosis................................................................................................14950
Electronic Ignition System Diagnosis................................................................................................14955
EVAP Canister Purge Solenoid and EVAP Vacuum Switch.................................................................................14955
Visual Check of The Evaporative Emission Canister...................................................................................14955
Fuel Metering System Check..........................................................................................................14955
Fuel System Pressure Test...........................................................................................................14955
Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure..........................................................14955
Powertrain Control Module (PCM) Diagnosis...........................................................................................14960
Multiple PCM Information Sensor DTCs Set............................................................................................14960
Exhaust Gas Recirculation (EGR) Diagnosis...........................................................................................14963
Engine Tech 2 Data Definitions and Ranges...........................................................................................14963
Typical Scan Data Values............................................................................................................14965
No Malfunction Indicator Lamp (MIL).................................................................................................14971
Malfunction Indicator Lamp (MIL) “ON” Steady........................................................................................14974
No Reduced Power Lamp (RPL).........................................................................................................14976
Reduced Power Lamp (RPL) “ON” Steady................................................................................................14980
Engine Cranks But Will Not Run......................................................................................................14983
Fuel System Electrical Test.........................................................................................................14990
Electric Throttle Control (ETC) System Check........................................................................................14994
Exhaust Gas Recirculation (EGR) System Check........................................................................................15003
Circuit Description.............................................................................................................15003
Manifold Absolute Pressure (MAP) Output Check.......................................................................................15005
Evaporative (EVAP) Emissions Canister Purge Valve Check.............................................................................15007
Upshift Lamp System Check (Manual Transmisssion Only)...............................................................................15010
PCM Diagnostic Trouble Codes........................................................................................................15014
Diagnostic Trouble Code (DTC) P0101 MAF System Performance..........................................................................15018
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency................................................................15021
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency...............................................................15024
Diagnostic Trouble Code (DTC) P0106 MAP System Performance..........................................................................15027
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage..................................................................15030
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage.................................................................15033
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage..................................................................15036
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage.................................................................15039
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage..................................................................15042
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage.................................................................15045
Diagnostic Trouble Code (DTC)
P0125 ECT Excessive Time to Closed Loop Fuel Control..................................................15048
Diagnostic Trouble Code(DTC)
P0128 Thermostat Insufficient temperrature for Stable Opreation........................................15051
Diagnostic Trouble Code (DTC)
P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1........................................................15054
Diagnostic Trouble Code (DTC)
P0132 HO2S Circuit High Voltage Bank 1 Sensor 1.......................................................15057
Diagnostic Trouble Code (DTC)
P0133 HO2S Slow Response Bank 1 Sensor 1..............................................................15060
Diagnostic Trouble Code (DTC)
P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1..............................................15064
Diagnostic Trouble Code (DTC)
P0135 HO2S Heater Circuit Bank 1 Sensor 1.............................................................15067
Diagnostic Trouble Code (DTC)
P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2........................................................15070
Diagnostic Trouble Code (DTC)
P0138 HO2S Circuit High Voltage Bank 1 Sensor 2.......................................................15073
Diagnostic Trouble Code(DTC)
P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2...............................................15076
Diagnostic Trouble Code (DTC)
P0141 HO2S Heater Circuit Bank 1 Sensor 2.............................................................15079
Diagnostic Trouble Code (DTC)
P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1........................................................15082
Diagnostic Trouble Code (DTC)
P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1.......................................................15085
Diagnostic Trouble Code (DTC)
P0153 HO2S Slow Response Bank 2 Sensor 1..............................................................15088
Diagnostic Trouble Code (DTC)
P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1..............................................15092
Diagnostic Trouble Code (DTC)
P0155 HO2S Heater Circuit Open Bank 2 Sensor 1........................................................15095
Diagnostic Trouble Code (DTC)
P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2........................................................15098
Diagnostic Trouble Code (DTC)
P0158 HO2S Circuit High Voltage Bank 2 Sensor 2.......................................................15101
Diagnostic Trouble Code (DTC)
P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2..............................................15104
Diagnostic Trouble Code (DTC)
P0161 HO2S Heater Circuit Bank 2 Sensor 2.............................................................15107
Diagnostic Trouble Code (DTC)
P0171 Fuel Trim System Lean Bank 1....................................................................15110
Diagnostic Trouble Code (DTC)
P0172 Fuel Trim System Rich Bank 1....................................................................15114
Diagnostic Trouble Code (DTC)
P0174 Fuel Trim System Lean Bank 2....................................................................15118
Diagnostic Trouble Code (DTC)
P0175 Fuel Trim System Rich Bank 2....................................................................15122
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit......................................................................15126
Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit......................................................................15129
Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit......................................................................15132
Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit......................................................................15135
Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit......................................................................15138
Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit......................................................................15141
Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected.........................................................................15144
Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected.......................................................................15148
Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected.......................................................................15150
Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected.......................................................................15152
Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected.......................................................................15154
Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected.......................................................................15156
Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected.......................................................................15158
Diagnostic Trouble Code (DTC) P0325 ION Sensing Module/ION Sensing
Knock Intensity Circuit Fault....................................15160
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit....................................................................15163
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency................................................................15166
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit......................................................................15169
Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit......................................................................15172
Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit......................................................................15175
Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit......................................................................15178
Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit......................................................................15181
Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit......................................................................15184
Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient...........................................................................15187
Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error..........................................................................15190
Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck..................................................................................15192
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage.................................................................................15194
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage................................................................................15197
Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1................................................................15200
Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2................................................................15203
Diagnostic Trouble Code (DTC) P0440 EVAP System.....................................................................................15206
Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected.................................................................15209
Diagnostic Trouble Code (DTC) P0444 EVAP Purge Control Circuit Open.................................................................15212
Diagnostic Trouble Code (DTC) P0445 EVAP Purge Control Circuit Short................................................................15214
Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Control Malfunction..........................................................15216
Diagnostic Trouble Code (DTC) P0447 EVAP Vent Solenoid Circuit Open.................................................................15219
Diagnostic Trouble Code (DTC) P0448 EVAP Vent solenoid Circuit Short................................................................15221
Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor Low Voltage...........................................................15223
Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor
(Vapor pressure Sensor) High Voltage..................................15226
Diagnostic Trouble Code (DTC) P0456 EVAP Very Small Leak............................................................................15229
Diagnostic Trouble Code (DTC) P0461 Fuel Level Sensor Performance...................................................................15232
Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit–Low Voltage...........................................................15234
Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit–High Voltage..........................................................15237
Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Noisy Signal..................................................................15239
Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input...........................................................................15241
Diagnostic Trouble Code (DTC)
P0506 Idle Air Control System Low RPM.................................................................15244
Diagnostic Trouble Code (DTC)
P0507 Idle Air Control System High RPM................................................................15247
Diagnostic Trouble Code (DTC) P0562 System Voltage Low..............................................................................15250
Diagnostic Trouble Code (DTC) P0563 System Voltage High.............................................................................15252
Diagnostic Trouble Code (DTC)
P0565 Cruise Main Switch Circuit Error................................................................15254
Diagnostic Trouble Code (DTC)
P0566 Cruise Cansel Switch Circuit Error..............................................................15256
Diagnostic Trouble Code (DTC)
P0567 Cruise Resume Switch Circuit Error..............................................................15258
Diagnostic Trouble Code (DTC)
P0568 Cruise Set Switch Circuit Error.................................................................15260
Diagnostic Trouble Code (DTC) P0571 No Break Switch Signal..........................................................................15262
Diagnostic Trouble Code (DTC) P0601 PCM Memory......................................................................................15264
Diagnostic Trouble Code (DTC) P0602 PCM Programming Error...........................................................................15266
Diagnostic Trouble Code (DTC) P0604 PCM RAM Error...................................................................................15268
Diagnostic Trouble Code (DTC) P0606 PCM Internal Performance........................................................................15270
Diagnostic Trouble Code (DTC)
P1106 MAP Sensor Circuit Intermittent High Voltage....................................................15272
Diagnostic Trouble Code (DTC)
P1107 MAP Circuit Intermittent Low Voltage............................................................15274
Diagnostic Trouble Code (DTC)
P1111 IAT Sensor Circuit Intermittent High Voltage....................................................15276
Diagnostic Trouble Code (DTC)
P1112 IAT Sensor Circuit Intermittent Low Voltage.....................................................15279
Diagnostic Trouble Code (DTC)
P1114 ECT Sensor Circuit Intermittent Low Voltage.....................................................15281
Diagnostic Trouble Code (DTC)
P1115 ECT Sensor Circuit Intermittent High Voltage....................................................15283
Diagnostic Trouble Code (DTC)
P1120-TPS 1 Throttle Position Sensor (TPS1) Output Abnormal...........................................15286
Diagnostic Trouble Code (DTC)
P1125 ETC (Electric throttle control) Limit Performance Mode..........................................15289
Diagnostic Trouble Code (DTC)
P1133 HO2S Insufficient Switching Bank 1 Sensor 1.....................................................15292
Diagnostic Trouble Code (DTC)
P1134 HO2S Transition Time Ratio Bank 1 Sensor 1......................................................15296
Diagnostic Trouble Code (DTC)
P1153 HO2S Insufficient Switching Bank 2 Sensor 1.....................................................15300
Diagnostic Trouble Code (DTC)
P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1..............................................15304
Diagnostic Trouble Code (DTC)
P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1).............................................15308
Diagnostic Trouble Code (DTC)
P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2).............................................15310
Diagnostic Trouble Code (DTC)
P1171 Fuel System Lean During Acceleration............................................................15312
Diagnostic Trouble Code (DTC)
P1220 Throttle Position Senser2 (TPS2) Circuit Fault..................................................15315
Diagnosis Truble Code(DTC) P1221 TPS1 – TPS2 correlation(Circuit Performance).......................................................15318
Diagnostic Trouble Code (DTC) P1271 APS 1– 2 Correlation Error......................................................................15321
Diagnostic Trouble Code (DTC) P1272 APS 2 – 3 Correlation Error.....................................................................15324
Diagnostic Trouble Code (DTC) P1273 APS 1 – 3 Correlation Error.....................................................................15327
Diagnostic Trouble Code (DTC) P1275 APS 1 Output Fault..............................................................................15330
Diagnostic Trouble Code (DTC) P1280 APS 2 Output Fault..............................................................................15332
Diagnostic Trouble Code (DTC) P1285 APS 3 Output Fault..............................................................................15334
Diagnostic Trouble Code (DTC) P1290 ETC Forced Idle Mode............................................................................15336
Diagnostic Trouble Code (DTC) P1295 ETC Power Management Mode.......................................................................15339
Diagnostic Trouble Code (DTC)
P1299 ETC Forced Engine Shutdown Mode.................................................................15343
Diagnostic Trouble Code (DTC) P1310 ION Sensing Module Diagnosis....................................................................15347
Diagnostic Trouble Code (DTC)
P1311 ION Sensing Module SEC line 1 Circuit Fault.....................................................15350
Diagnostic Trouble Code (DTC)
P1312 ION Sensing Module SEC line 2 Circuit Fault.....................................................15353
Diagnostic Trouble Code (DTC)
P1326 ION Sensing Module Combustion Quality Input Circuit Fault.......................................15356
Diagnostic Trouble Code (DTC)
P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)............................15359
Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed................................................................................15362
Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge...............................................................15365
Diagnostic Trouble Code (DTC) P1514 TPS - MAF Correlation Error.....................................................................15368
Diagnostic Trouble Code (DTC)
P1515 Command - Actual TPS Correlation Error..........................................................15372
Diagnostic Trouble Code (DTC)
P1516 Command - Actual TPS Correlation Error..........................................................15375
Diagnostic Trouble Code (DTC)
P1523 Actuator Control Return Performance.............................................................15378
Diagnostic Trouble Code (DTC) P1571 Break Switch No Operation.......................................................................15381
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset............................................................................15383
Diagnostic Trouble Code (DTC)
P1635 Reference Voltage # 1 Circuit Fault.............................................................15384
Diagnostic Trouble Code (DTC)
P1639 Reference Voltage # 2 Circuit Fault.............................................................15386
Diagnostic Trouble Code (DTC)
P1640 Driver-1-Output Circuit Fault (ODM).............................................................15388
Diagnostic Trouble Code (DTC) P1650 Quad Driver Module “A” Fault....................................................................15391
Default Matrix Table................................................................................................................15423
Crankshaft Position (CKP)
Sensor....................................................................................................15426
Engine Coolant Temperature
(ECT) Sensor.............................................................................................15426
Heated Oxygen Sensor (HO2S).........................................................................................................15427
Intake Air Temperature (IAT) Sensor.................................................................................................15430
ION Sensing Module..................................................................................................................15430
Mass Air Flow (MAF) Sensor..........................................................................................................15431
Manifold Absolute Pressure (MAP) Sensor.............................................................................................15432
Malfunction Indicator Lamp (MIL)....................................................................................................15433
Reduced Power Lamp..................................................................................................................15433
Powertrain Control Module (PCM).....................................................................................................15433
Service Precaution..............................................................................................................15433
Installation Procedure..........................................................................................................15434
EEPROM..............................................................................................................................15435
Throttle Position (TP) Sensor.......................................................................................................15436
Vehicle Speed Sensor (VSS)..........................................................................................................15436
Air Cleaner/Air Filter..............................................................................................................15438
Common Chamber......................................................................................................................15438
Accelerator Pedal Replacement.......................................................................................................15439
Accelerator Position Sensor Replacement.............................................................................................15440
Accelerator Position Sensor Adjustment..............................................................................................15440
Fuel Filler Cap.....................................................................................................................15441
Fuel Filter.........................................................................................................................15441
Fuel Gauge Unit.....................................................................................................................15442
Fuel Injectors......................................................................................................................15443
Fuel Metering System................................................................................................................15444
Fuel Pump Assembly..................................................................................................................15444
Fuel Pump Relay.....................................................................................................................15444
Fuel Rail Assembly..................................................................................................................15445
Fuel Tank...........................................................................................................................15446
Throttle Body (TB)..................................................................................................................15446
Electronic Ignition System..........................................................................................................15448
Catalytic Converter.................................................................................................................15449
Air Conditioning Thermo Relay.......................................................................................................15449
EVAP Canister Hoses.................................................................................................................15450
EVAP Canister.......................................................................................................................15450
EVAP Canister Vent Solenoid.........................................................................................................15452
Fuel Tank Pressure Sensor...........................................................................................................15453
EVAP Canister Purge Solenoid........................................................................................................15453
Fuel Tank Vent Valve................................................................................................................15454
Linear Exhaust Gas Recirculation (EGR) Valve........................................................................................15455
Positive Crankcase Ventilation
(PCV) Valve..........................................................................................15456
Wiring and Connectors...............................................................................................................15456
PCM Connectors and Terminals........................................................................................................15457
Wire Harness Repair: Twisted
Shielded Cable.........................................................................................15457
Twisted Leads.......................................................................................................................15458
Weather-Pack Connector..............................................................................................................15459
Com-Pack III........................................................................................................................15460
Metri-Pack..........................................................................................................................15460
General Description (PCM and Sensors)...............................................................................................15462
A/C Request Signal..............................................................................................................15462
Crankshaft Position (CKP) Sensor................................................................................................15462
Engine Coolant Temperature (ECT) Sensor.........................................................................................15462
Electrically Erasable Programmable Read
Only Memory (EEPROM)....................................................................15462
Fuel Control Heated Oxygen Sensors..............................................................................................15462
Catalyst Monitor Heated Oxygen Sensors..........................................................................................15463
Intake Air Temperature (IAT) Sensor.............................................................................................15463
Linear Exhaust Gas Recirculation (EGR) Control..................................................................................15464
Mass Air Flow (MAF) Sensor......................................................................................................15464
Manifold Absolute Pressure (MAP) Sensor.........................................................................................15464
Powertrain Control Module (PCM).................................................................................................15465
PCM Function....................................................................................................................15465
PCM Components..................................................................................................................15465
PCM Voltage Description.........................................................................................................15465
PCM Input/Outputs...............................................................................................................15465
PCM Service Precautions.........................................................................................................15466
Reprogramming The PCM...........................................................................................................15466
Throttle Position (TP) Sensor...................................................................................................15466
Transmission Fluid Temperature (TFT) Sensor.....................................................................................15466
Transmission Range Switch.......................................................................................................15466
Vehicle Speed Sensor (VSS)......................................................................................................15466
Use of Circuit Testing Tools....................................................................................................15466
Aftermarket Electrical and Vacuum Equipment.....................................................................................15467
Electrostatic Discharge Damage..................................................................................................15467
Upshift Lamp....................................................................................................................15467
General Description (Air Induction).................................................................................................15467
General Description (Fuel Metering).................................................................................................15468
Battery Voltage Correction Mode.................................................................................................15468
Clear Flood Mode................................................................................................................15468
Deceleration Mode...............................................................................................................15468
Engine Speed/Vehicle Speed/Fuel Disable Mode....................................................................................15468
Fuel Cutoff Mode................................................................................................................15468
Fuel Injector...................................................................................................................15468
Fuel Metering System Components.................................................................................................15468
Fuel Metering System Purpose....................................................................................................15468
Fuel Pressure Regulator.........................................................................................................15469
Fuel Pump Electrical Circuit....................................................................................................15469
Fuel Rail.......................................................................................................................15469
Run Mode........................................................................................................................15469
Starting Mode...................................................................................................................15469
Throttle Body Unit..............................................................................................................15470
General Description (Electronic
Ignition System)....................................................................................15470
Electronic Ignition.............................................................................................................15470
Ignition Coils..................................................................................................................15470
Ignition Control................................................................................................................15470
Ignition Control PCM Output.....................................................................................................15471
Powertrain Control Module (PCM).................................................................................................15471
Spark Plug......................................................................................................................15472
A/C Clutch Diagnosis................................................................................................................15473
A/C Clutch Circuit Purpose......................................................................................................15473
A/C Request Signal..............................................................................................................15473
General Description (Evaporative (EVAP) Emission System)............................................................................15474
EVAP Emission Control System Operation..........................................................................................15474
General Description (Exhaust Gas Recirculation (EGR) System)........................................................................15479
Linear EGR Valve................................................................................................................15479
Linear EGR Control..............................................................................................................15479
Linear EGR Valve Operation and Results
of Incorrect Operation...................................................................15479
EGR Pintle Position Sensor......................................................................................................15480
General Description (Positive
Crankcase Ventilation (PCV) System)...................................................................15480
Crankcase Ventilation System Operation..........................................................................................15480
Special Tools.......................................................................................................................15482
6F ENGINE EXHAUST......................................................................................................................15484
Service Precaution..................................................................................................................15484
General Description.................................................................................................................15485
Three Way Catalytic Converter RH and Forked Exhaust Pipe............................................................................15486
Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated
Parts...................................................15486
Removal.........................................................................................................................15486
Installation....................................................................................................................15486
Three Way Catalytic Converter LH and Forked Exhaust Pipe............................................................................15487
Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated
Parts...................................................15487
Removal.........................................................................................................................15487
Installation....................................................................................................................15487
Forked Exhaust Pipe.................................................................................................................15488
Forked Exhaust Pipe and Associated Parts........................................................................................15488
Removal.........................................................................................................................15488
Installation....................................................................................................................15488
Exhaust Silencer....................................................................................................................15489
Exhaust Silencer and Associated Parts...........................................................................................15489
Removal.........................................................................................................................15489
Installation....................................................................................................................15489
Rear Exhaust pipe...................................................................................................................15490
Rear Exhaust pipe and Associated Parts..........................................................................................15490
Removal.........................................................................................................................15490
Installation....................................................................................................................15490
Main Data and Specifications........................................................................................................15491
6G ENGINE LUBRICATION..................................................................................................................15492
Service Precaution..................................................................................................................15492
General Description.................................................................................................................15493
Oil Pump............................................................................................................................15494
Oil Pump and Associated Parts...................................................................................................15494
Disassembly.....................................................................................................................15495
Inspection and Repair...........................................................................................................15495
Reassembly......................................................................................................................15496
Oil Pan and Crankcase...............................................................................................................15498
Removal.........................................................................................................................15498
Installation....................................................................................................................15498
Oil Pump............................................................................................................................15500
Removal.........................................................................................................................15500
Installation....................................................................................................................15500
Oil Pump Oil Seal...................................................................................................................15502
Removal.........................................................................................................................15502
Installation....................................................................................................................15502
Oil Filter..........................................................................................................................15503
Removal.........................................................................................................................15503
Installation....................................................................................................................15503
Main Data and Specification.........................................................................................................15504
6H ENGINE SPEED CONTROL SYSTEM.........................................................................................................15505
Service Precaution..................................................................................................................15505
Accelerator Pedal...................................................................................................................15506
Accelerator Pedal and Associated Parts..........................................................................................15506
Removal.........................................................................................................................15506
Installation....................................................................................................................15506
6J INDUCTION...........................................................................................................................15507
Service Precaution..................................................................................................................15507
Air Cleaner Element.................................................................................................................15508
Removal.........................................................................................................................15508
Inspection......................................................................................................................15508
Installation....................................................................................................................15508
Sec.7 TRANSMISSION..............................................................................................................................15509
7A AUTOMATIC TRANSMISSION..................................................................................................................15509
Service Precaution......................................................................................................................15510
Construction............................................................................................................................15511
Range Reference Chart...................................................................................................................15512
Normal Operation of 2001 4L30–E Transmission............................................................................................15513
Diagnosis...............................................................................................................................15513
Driver Information......................................................................................................................15513
General Diagnosis Procedure.............................................................................................................15516
Preliminary Inspection Chart............................................................................................................15517
Checking Transmission Fluid Level
and Condition.........................................................................................15518
Test Driving............................................................................................................................15519
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................15520
Mechanical / Hydraulic Diagnosis Symptoms Index.........................................................................................15521
Stall Test..............................................................................................................................15530
Line Pressure Test......................................................................................................................15531
Shift Speed Chart (V6)..................................................................................................................15533
Lockup Speed Chart (V6).................................................................................................................15534
Shift Speed Chart (HEC).................................................................................................................15535
Lockup Speed Chart (HEC)................................................................................................................15536
Changing Transmission Fluid.............................................................................................................15537
Selector Lever..........................................................................................................................15537
Inspection..........................................................................................................................15537
Removal.............................................................................................................................15537
Installation........................................................................................................................15539
Select Cable............................................................................................................................15539
Removal.............................................................................................................................15539
Installation........................................................................................................................15542
Shift Lock Cable........................................................................................................................15544
Removal.............................................................................................................................15544
Installation........................................................................................................................15544
Mode Switch.............................................................................................................................15545
Removal.............................................................................................................................15545
Installation........................................................................................................................15546
Transmission Assembly...................................................................................................................15547
Transmission and Associated Parts...................................................................................................15547
Removal.............................................................................................................................15549
Installation........................................................................................................................15556
Solenoid (Main Case Valve Body).........................................................................................................15563
Removal.............................................................................................................................15563
Installation........................................................................................................................15563
Solenoid (Adapter Case Valve Body)......................................................................................................15564
Removal.............................................................................................................................15564
Installation........................................................................................................................15564
Valve Body Assembly (Main Case).........................................................................................................15565
Removal.............................................................................................................................15565
Installation........................................................................................................................15565
Valve Body Assembly (Adapter Case)......................................................................................................15566
Removal.............................................................................................................................15566
Installation........................................................................................................................15566
Powertrain Control Module (PCM) (V6)....................................................................................................15567
Removal.............................................................................................................................15567
Installation........................................................................................................................15567
Powertrain Control Module (PCM) (HEC)...................................................................................................15568
Removal.............................................................................................................................15568
Installation........................................................................................................................15568
Speed Sensor (Extension Assembly).......................................................................................................15569
Removal.............................................................................................................................15569
Installation........................................................................................................................15569
Transmission Oil Temperature Sensor (Main Case) (V6)....................................................................................15570
Removal.............................................................................................................................15570
Installation........................................................................................................................15570
Transmission Oil Temperature Sensor (Adapter Case) (HEC)................................................................................15571
Removal.............................................................................................................................15571
Installation........................................................................................................................15571
Front Oil Seal (Converter Housing)......................................................................................................15572
Removal.............................................................................................................................15572
Installation........................................................................................................................15572
Rear Oil Seal (Extension Assembly)......................................................................................................15573
Removal.............................................................................................................................15573
Installation........................................................................................................................15573
Transmission (4L30–E)...................................................................................................................15574
Disassembly.........................................................................................................................15574
Reassembly..........................................................................................................................15579
Converter Housing and Oil Pump Assembly.................................................................................................15590
Disassembled View...................................................................................................................15590
Disassembly.........................................................................................................................15590
Inspection and Repair...............................................................................................................15590
Reassembly..........................................................................................................................15590
Oil Pump................................................................................................................................15591
Disassembled View...................................................................................................................15591
Disassembly.........................................................................................................................15591
Inspection and Repair...............................................................................................................15591
Reassembly..........................................................................................................................15591
Main Case Valve Body....................................................................................................................15592
Disassembled View...................................................................................................................15592
Disassembly.........................................................................................................................15593
Inspection and Repair...............................................................................................................15593
Reassembly..........................................................................................................................15593
Adapter Case Valve Body.................................................................................................................15594
Disassembled View...................................................................................................................15594
Disassembly.........................................................................................................................15594
Inspection and Repair...............................................................................................................15594
Reassembly..........................................................................................................................15594
Third Clutch and Sprag Unit.............................................................................................................15595
Disassembled View...................................................................................................................15595
Disassembly.........................................................................................................................15595
Inspection and Repair...............................................................................................................15596
Reassembly..........................................................................................................................15596
Third Clutch............................................................................................................................15596
Disassembled View...................................................................................................................15596
Disassemble.........................................................................................................................15597
Inspection and Repair...............................................................................................................15597
Reassembly..........................................................................................................................15597
Sprag Unit..............................................................................................................................15598
Disassembled View...................................................................................................................15598
Disassembly.........................................................................................................................15598
Inspection and Repair...............................................................................................................15598
Reassembly..........................................................................................................................15598
Second Clutch...........................................................................................................................15599
Disassembled View...................................................................................................................15599
Disassembly.........................................................................................................................15599
Inspection and Repair...............................................................................................................15600
Reassembly..........................................................................................................................15600
3–4 Accumulator Piston..................................................................................................................15601
Disassembled View...................................................................................................................15601
Disassembly.........................................................................................................................15601
Inspection and Repair...............................................................................................................15602
Reassembly..........................................................................................................................15602
Reverse Clutch Piston and Center Support................................................................................................15603
Disassembled View...................................................................................................................15603
Disassembly.........................................................................................................................15604
Inspection and Repair...............................................................................................................15604
Reassembly..........................................................................................................................15604
Overrun Clutch and Turbine Shaft........................................................................................................15605
Disassembled View...................................................................................................................15605
Disassembly.........................................................................................................................15606
Inspection and Repair...............................................................................................................15606
Reassembly..........................................................................................................................15606
Main Data and Specification.............................................................................................................15608
General Specifications..............................................................................................................15608
Torque Specifications...............................................................................................................15609
Special Tools...........................................................................................................................15614
4L30–E Parts List.......................................................................................................................15617
7A1 TRANSMISSION CONTROL SYSTEM.............................................................................................................15624
Service Precaution......................................................................................................................15625
General Description.....................................................................................................................15625
Electronic Control Diagram..........................................................................................................15626
Powertrain Control Module (PCM).....................................................................................................15627
Control System Diagram..............................................................................................................15628
Shift Control.......................................................................................................................15629
Band Apply Control..................................................................................................................15629
Torque Converter Clutch Control.....................................................................................................15629
Line Pressure Control...............................................................................................................15629
On–Board Diagnostic System..........................................................................................................15629
Fail–Safe Mechanism.................................................................................................................15629
Torque Management Control...........................................................................................................15629
ATF Warning Control.................................................................................................................15629
Reverse Lock Out Control............................................................................................................15629
Downhill Control....................................................................................................................15629
Uphill Control......................................................................................................................15629
Shift Mode Control..................................................................................................................15630
Gear Shift Control..................................................................................................................15631
Winter Drive Mode...................................................................................................................15632
Backup Mode.........................................................................................................................15632
Functions of Input / Output Components..............................................................................................15633
Diagnosis...............................................................................................................................15634
Electronic Diagnosis................................................................................................................15634
Check Trans Indicator...............................................................................................................15634
Diagnostic Check....................................................................................................................15634
“Check Trans” Check.................................................................................................................15635
Tech 2 OBD II Connection............................................................................................................15636
Transmission Data...................................................................................................................15641
OBD II Diagnostic Management System.................................................................................................15642
16 – Terminal Data Link Connector (DLC).............................................................................................15643
Malfunction Indicator Lamp (MIL)....................................................................................................15644
DTC Types...........................................................................................................................15644
Clear DTC...........................................................................................................................15645
DTC Check...........................................................................................................................15645
PCM Precaution......................................................................................................................15645
Information On PCM..................................................................................................................15645
Intermittent Conditions.............................................................................................................15646
Transmission and PCM Identification.................................................................................................15647
Diagnostic Trouble Code (DTC)
Identification........................................................................................15648
DTC P0218 Transmission Fluid Over Temperature...........................................................................................15649
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position......................................................................15651
DTC P0706 Transmission Range Switch (Mode Switch) Performance...........................................................................15654
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance.......................................................................15657
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input.................................................................15660
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................15663
DTC P0719 Brake Switch Circuit Low (Stuck On)...........................................................................................15666
DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input....................................................................15669
DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent.................................................................15672
DTC P0724 Brake Switch Circuit High (Stuck Off).........................................................................................15675
DTC P0730 Gear Error Without Input Speed................................................................................................15677
DTC P0742 Torque Converter Clutch (TCC) System Stuck On.................................................................................15680
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical..............................................................15682
DTC P0751 Shift Solenoid A Performance (Stuck Off)......................................................................................15684
DTC P0752 Shift Solenoid A Performance (Stuck On).......................................................................................15686
DTC P0753 Shift Solenoid A Electrical...................................................................................................15688
DTC P0756 Shift Solenoid B Performance (Stuck Off)......................................................................................15691
DTC P0757 Shift Solenoid B Performance (Stuck On).......................................................................................15693
DTC P0758 Shift Solenoid B Electrical...................................................................................................15695
DTC P1850 Brake Band Apply Solenoid Malfunction.........................................................................................15699
DTC P1860 TCC Solenoid Electrical.......................................................................................................15703
DTC P1870 Transmission Component Slipping (TCC Stuck Off)...............................................................................15706
Circuit Diagram.........................................................................................................................15708
Parts Location..........................................................................................................................15710
Harness Connector Faces.................................................................................................................15711
7B MANUAL TRANSMISSION MUA 5C..............................................................................................................15713
Service Precaution......................................................................................................................15713
General Description.....................................................................................................................15714
Diagnosis...............................................................................................................................15716
Rear Oil Seal (4X2).....................................................................................................................15717
Disassembled View...................................................................................................................15717
Removal.............................................................................................................................15717
Installation........................................................................................................................15717
Transmission............................................................................................................................15718
Disassembled View...................................................................................................................15718
Removal.............................................................................................................................15719
Installation........................................................................................................................15723
Transmission Case.......................................................................................................................15728
Major Component (4X2)...............................................................................................................15728
Disassembly.........................................................................................................................15729
Reassembly..........................................................................................................................15730
Transmission Case and Transfer Case.....................................................................................................15733
Major Component (4X4)...............................................................................................................15733
Disassembly.........................................................................................................................15734
Reassembly..........................................................................................................................15737
Intermediate Plate with Gear Assembly, Detent, Shift Arm,
and Interlock Pin.............................................................15743
Disassembled View...................................................................................................................15743
Disassembly.........................................................................................................................15744
Inspection and Repair...............................................................................................................15745
Reassembly..........................................................................................................................15746
Reverse Gear and 5th Gear...............................................................................................................15747
Disassembled View...................................................................................................................15747
Disassembly.........................................................................................................................15748
Inspection and Repair...............................................................................................................15750
Reassembly..........................................................................................................................15750
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft.................................................................................15756
Disassmebled View...................................................................................................................15756
Disassembly.........................................................................................................................15757
Inspection and Repair...............................................................................................................15758
Reassembly..........................................................................................................................15761
Main Data and Specifications............................................................................................................15767
Special Tools (MUA).....................................................................................................................15771
7C CLUTCH..................................................................................................................................15773
Service Precaution......................................................................................................................15773
General Description.....................................................................................................................15774
Diagnosis...............................................................................................................................15779
Clutch Assembly (Y22SE).................................................................................................................15780
Clutch Assembly (Y22SE) and Associated Parts........................................................................................15780
Removal.............................................................................................................................15780
Inspection and Repair...............................................................................................................15781
Installation........................................................................................................................15785
Clutch Assembly (6VD1)..................................................................................................................15787
Clutch Assembly (6VD1) and Associated Parts.........................................................................................15787
Removal.............................................................................................................................15787
Inspection and Repair...............................................................................................................15789
Installation........................................................................................................................15793
Clutch Control..........................................................................................................................15795
Parts Location View.................................................................................................................15795
Removal.............................................................................................................................15796
Inspection and Repair...............................................................................................................15796
Installation........................................................................................................................15796
Master Cylinder.........................................................................................................................15799
Slave Cylinder..........................................................................................................................15800
Disassembled View...................................................................................................................15800
Disassembly.........................................................................................................................15800
Inspection and Repair...............................................................................................................15800
Reassembly..........................................................................................................................15801
Main Data and Specifications............................................................................................................15802
Special Tools...........................................................................................................................15805
Sec.8 BODY AND ACCESSORIES......................................................................................................................15806
8A LIGHTING SYSTEM..........................................................................................................................15806
Service Precaution......................................................................................................................15807
Headlight Bulb..........................................................................................................................15808
Headlight Assembly......................................................................................................................15808
Headlight Adjustment................................................................................................................15809
Fog Light Bulb..........................................................................................................................15811
Fog Light Assembly......................................................................................................................15812
Fog Light Adjustment................................................................................................................15812
Side Marker Light Bulb..................................................................................................................15812
Taillight Bulb..........................................................................................................................15813
License Plate Light Bulb (Bumper Type)..................................................................................................15813
License Plate Light Bulb (Tailgate Type)................................................................................................15814
Stoplight Bulb..........................................................................................................................15814
High Mounted Stoplight Assembly.........................................................................................................15815
High Mounted Stoplight Bulb.............................................................................................................15815
High Mounted Stoplight Assembly (Soft Top Model)........................................................................................15816
High Mounted Stoplight Bulb (Soft Top Model)............................................................................................15816
High Mounted Stoplight Assembly (Resin Top Model).......................................................................................15817
High Mounted Stoplight Bulb (Resin Top Model)...........................................................................................15817
Backup Light Bulb.......................................................................................................................15818
Front Turn Signal Light Bulb............................................................................................................15818
Rear Turn Signal Light Bulb.............................................................................................................15819
Dome Light Bulb (LWB)...................................................................................................................15819
Dome Light Bulb (SWB)...................................................................................................................15820
Courtesy Light Bulb.....................................................................................................................15820
Spotlight Bulb..........................................................................................................................15821
Luggage Room Light Bulb (LWB)...........................................................................................................15821
Luggage Room Light Bulb (Resin Top Model)...............................................................................................15822
HVAC Bezel Illumination Light Bulb......................................................................................................15822
Shift Lever Illumination Light Bulb (A/T)...............................................................................................15823
Vanity Mirror Illumination Light Bulb...................................................................................................15823
Starter Switch..........................................................................................................................15824
Lighting Switch (Combination Switch)....................................................................................................15824
Dimmer・Passing Switch (Combination Switch)..............................................................................................15824
Door Switch.............................................................................................................................15824
Rear Defogger Switch....................................................................................................................15825
Key Remind Switch (Starter Switch)......................................................................................................15825
Hazard Warning Light Switch.............................................................................................................15826
Stoplight Switch........................................................................................................................15826
Backup Light Switch (M/T)...............................................................................................................15827
Turn Signal Light Switch (Combination Switch)...........................................................................................15827
Illumination Controller.................................................................................................................15828
Light and Bulb Specifications (LWB).....................................................................................................15829
Light and Bulb Specifications (SWB).....................................................................................................15830
8B WIPER / WASHER SYSTEM....................................................................................................................15832
Service Precaution......................................................................................................................15832
Windshield Wiper/Washer System..........................................................................................................15833
General Description.....................................................................................................................15833
Windshield Wiper And Washer Switch......................................................................................................15833
Removal and Installation............................................................................................................15833
Windshield Wiper Motor..................................................................................................................15833
Removal.............................................................................................................................15833
Installation........................................................................................................................15833
Windshield Washer Motor.................................................................................................................15834
Removal.............................................................................................................................15834
Installation........................................................................................................................15834
Windshield Washer Spray Pattern.........................................................................................................15835
Windshield Wiper Linkage............................................................................................................15836
Windshield Wiper Linkage and Associated Parts.......................................................................................15836
Removal.............................................................................................................................15836
Installation........................................................................................................................15836
Windshield Wiper Arm/Blade..............................................................................................................15837
Removal.............................................................................................................................15837
Installation........................................................................................................................15837
Windshield Wiper Blade Rubber...........................................................................................................15838
Removal.............................................................................................................................15838
Installation........................................................................................................................15838
Rear Wiper/Washer System................................................................................................................15839
General Description.....................................................................................................................15839
Rear Wiper and Washer Switch............................................................................................................15839
Removal.............................................................................................................................15839
Installation........................................................................................................................15839
Rear Wiper Motor (LWB)..................................................................................................................15840
Removal.............................................................................................................................15840
Installation........................................................................................................................15840
Rear Wiper Motor (Resin Top Model)......................................................................................................15841
Removal.............................................................................................................................15841
Installation........................................................................................................................15841
Rear Washer Motor.......................................................................................................................15842
Removal.............................................................................................................................15842
Installation........................................................................................................................15842
Alarm and Relay Control Unit............................................................................................................15843
Removal.............................................................................................................................15843
Installation........................................................................................................................15843
Rear Wiper Arm/Blade (LWB)..............................................................................................................15843
Removal.............................................................................................................................15843
Installation........................................................................................................................15843
Rear Wiper Arm/Blade (Resin Top Model)..................................................................................................15844
Removal.............................................................................................................................15844
Installation........................................................................................................................15844
Rear Washer Nozzle......................................................................................................................15844
Removal.............................................................................................................................15844
Installation........................................................................................................................15844
Rear Washer Spray Pattern...........................................................................................................15844
Rear Washer Nozzle (Resin Top Model)....................................................................................................15845
Removal.............................................................................................................................15845
Installation........................................................................................................................15845
Rear Washer Spray Pattern...........................................................................................................15845
Rear Wiper Blade Rubber.................................................................................................................15846
Removal.............................................................................................................................15846
Installation........................................................................................................................15846
Main Data and Specifications............................................................................................................15847
8C ENTERTAINMENT............................................................................................................................15848
Service Precaution......................................................................................................................15848
Cigarette Lighter.......................................................................................................................15849
General Description.....................................................................................................................15849
Removal.............................................................................................................................15849
Installation........................................................................................................................15849
Digital Clock...........................................................................................................................15849
Removal.............................................................................................................................15849
Installation........................................................................................................................15849
Rod Type Antenna........................................................................................................................15850
Removal.............................................................................................................................15850
Installation........................................................................................................................15850
Accessory Socket........................................................................................................................15851
Front Accessory Socket..............................................................................................................15851
Rear Accessory Socket...............................................................................................................15851
Radio...................................................................................................................................15852
Removal.............................................................................................................................15852
Installation........................................................................................................................15852
Speaker.................................................................................................................................15853
Front Speaker.......................................................................................................................15853
Tweeter Assembly....................................................................................................................15853
Rear Door Speaker (LWB).............................................................................................................15853
Rear Speaker (LWB)..................................................................................................................15854
Rear Speaker (SWB)..................................................................................................................15854
Horn....................................................................................................................................15855
Removal.............................................................................................................................15855
Installation........................................................................................................................15855
8D WIRING SYSTEM............................................................................................................................15856
Fuse, Relay and Diode...................................................................................................................15857
Relay / Fuse Box Location...........................................................................................................15857
Relay / Fuse Box (Instrument Panel).................................................................................................15858
Relay / Fuse Box (L4 Engine Room)...................................................................................................15859
Relay / Fuse Box (V6 Engine Room)...................................................................................................15860
Circuit Diagram.........................................................................................................................15861
8E METER AND GAUGE..........................................................................................................................15892
Service Precaution......................................................................................................................15892
General Description.....................................................................................................................15892
Meter Assembly..........................................................................................................................15893
General Description.....................................................................................................................15893
Layout for Meters/Gauges, Warning
Lights, Indicator Lights and
Illumination Lights..................................................15893
Table for Meter/Gauge Connector Terminal Connections................................................................................15895
Removal.............................................................................................................................15897
Installation........................................................................................................................15897
Warning Light Bulb and Indicator Light Bulb.............................................................................................15897
Removal.............................................................................................................................15897
Installation........................................................................................................................15897
A/T Shift Indicator Light Bulb..........................................................................................................15898
Removal.............................................................................................................................15898
Installation........................................................................................................................15899
Vehicle Speed Sensor....................................................................................................................15899
Removal.............................................................................................................................15899
Installation........................................................................................................................15899
Fuel Tank Unit..........................................................................................................................15900
Removal.............................................................................................................................15900
Installation........................................................................................................................15900
Main Data and Specifications............................................................................................................15901
8F BODY STRUCTURE...........................................................................................................................15902
Service Precaution......................................................................................................................15903
Frame...................................................................................................................................15903
General Description.....................................................................................................................15903
Frame Dimensions (LWB)..............................................................................................................15904
Frame Dimensions (SWB)..............................................................................................................15905
General Description (Bumper)............................................................................................................15906
Front Bumper............................................................................................................................15906
Parts Location......................................................................................................................15906
Removal.............................................................................................................................15907
Installation........................................................................................................................15907
Front Bumper Slider Bracket.............................................................................................................15908
Removal.............................................................................................................................15908
Installation........................................................................................................................15908
Rear Bumper.............................................................................................................................15909
Parts Location (Spare tire mounted tailgate model)..................................................................................15909
Removal.............................................................................................................................15910
Installation........................................................................................................................15910
Parts Location (Spare tire mounted under floor model)...............................................................................15912
Removal.............................................................................................................................15913
Installation........................................................................................................................15913
Rear Bumper Slider......................................................................................................................15914
Removal.............................................................................................................................15914
Installation........................................................................................................................15914
General Description (Sheet Metal).......................................................................................................15915
Engine Hood.............................................................................................................................15915
Parts Location......................................................................................................................15915
Removal.............................................................................................................................15916
Installation........................................................................................................................15916
Engine Hood Lock........................................................................................................................15918
Parts Location......................................................................................................................15918
Removal.............................................................................................................................15918
Installation........................................................................................................................15919
Radiator Grille.........................................................................................................................15920
Parts Location......................................................................................................................15920
Removal.............................................................................................................................15920
Installation........................................................................................................................15921
Front Fender Panel......................................................................................................................15922
Parts Location......................................................................................................................15922
Removal.............................................................................................................................15922
Installation........................................................................................................................15923
Body Mounting...........................................................................................................................15925
Parts Location......................................................................................................................15925
Tightening Torque...................................................................................................................15925
Body Dimension..........................................................................................................................15926
Front Section.......................................................................................................................15926
Room Section (SWB)..................................................................................................................15929
Room Section (LWB)..................................................................................................................15931
Rear Section (SWB)..................................................................................................................15933
Rear Section (LWB)..................................................................................................................15935
Side Body Section (Front side)......................................................................................................15937
Side Body Section (Rear side).......................................................................................................15939
General Description (Body)..............................................................................................................15941
Instrument Panel Assembly...............................................................................................................15941
Parts Location......................................................................................................................15941
Removal.............................................................................................................................15942
Installation........................................................................................................................15943
Front Door Assembly.....................................................................................................................15944
Parts Location......................................................................................................................15944
Removal.............................................................................................................................15944
Installation........................................................................................................................15945
Rear Door Assembly......................................................................................................................15946
Parts Location......................................................................................................................15946
Removal.............................................................................................................................15946
Installation........................................................................................................................15947
Front Window Regulator, Glass and Glass Run.............................................................................................15948
Parts Location......................................................................................................................15948
Removal.............................................................................................................................15949
Installation........................................................................................................................15951
Rear Window Regulator, Glass and Glass Run..............................................................................................15952
Parts Location......................................................................................................................15952
Removal.............................................................................................................................15953
Installation........................................................................................................................15955
Tailgate (LWB)..........................................................................................................................15956
Parts Location......................................................................................................................15956
Removal.............................................................................................................................15957
Installation........................................................................................................................15958
Tailgate (SWB)..........................................................................................................................15959
Parts Location......................................................................................................................15959
Removal.............................................................................................................................15960
Installation........................................................................................................................15960
Rear Hatchgate (LWB)....................................................................................................................15961
Parts Location......................................................................................................................15961
Removal.............................................................................................................................15962
Installation........................................................................................................................15962
Adjustment..............................................................................................................................15964
Tailgate Glass (Resin Top)..............................................................................................................15965
Parts Location......................................................................................................................15965
Removal.............................................................................................................................15966
Installation........................................................................................................................15966
Spare Tire Carrier......................................................................................................................15967
Parts Location......................................................................................................................15967
Removal.............................................................................................................................15967
Installation........................................................................................................................15967
Spare Tire Hanger.......................................................................................................................15968
Parts Location......................................................................................................................15968
Removal.............................................................................................................................15969
Installation........................................................................................................................15969
Windshield..............................................................................................................................15970
Parts Location......................................................................................................................15970
Removal.............................................................................................................................15971
Installation........................................................................................................................15971
Rear Quarter Glass (LWB)................................................................................................................15974
Parts Location......................................................................................................................15974
Removal.............................................................................................................................15974
Installation........................................................................................................................15975
Rear Quarter Glass (Resin Top)..........................................................................................................15976
Parts Location......................................................................................................................15976
Removal.............................................................................................................................15976
Installation........................................................................................................................15976
Side Window Glass (SWB).................................................................................................................15978
Parts Location......................................................................................................................15978
Removal.............................................................................................................................15978
Installation........................................................................................................................15978
Main Data and Specifications............................................................................................................15979
Special Tools...........................................................................................................................15982
8G SEATS....................................................................................................................................15983
Service Precaution......................................................................................................................15983
Front Seat Assembly.....................................................................................................................15984
Front Seat Assembly and Associated Parts............................................................................................15984
Removal.............................................................................................................................15984
Installation........................................................................................................................15986
Power Seat Assembly.....................................................................................................................15987
Power Seat Assembly and Associated Parts............................................................................................15987
Removal.............................................................................................................................15988
Installation........................................................................................................................15989
Rear Seat Assembly (LWB)................................................................................................................15990
Rear Seat Cushion Assembly and Associated Parts.....................................................................................15990
Removal.............................................................................................................................15991
Installation........................................................................................................................15991
Rear Seat Back Assembly and Associated Parts........................................................................................15992
Removal.............................................................................................................................15992
Installation........................................................................................................................15993
Rear Seat Assembly (SWB)................................................................................................................15994
Rear Seat Assembly and Associated Parts.............................................................................................15994
Removal.............................................................................................................................15995
Installation........................................................................................................................15995
Main Data and Specifications............................................................................................................15996
8H SECURITY AND LOCKS.......................................................................................................................15998
Service Precaution......................................................................................................................15998
Front Door Lock Assembly................................................................................................................15999
Front Door Lock Assembly and Associated Parts.......................................................................................15999
Removal.............................................................................................................................16000
Installation........................................................................................................................16001
Front Outside Handle....................................................................................................................16002
Front Outside Handle and Associated Parts...........................................................................................16002
Removal.............................................................................................................................16002
Installation........................................................................................................................16002
Rear Door Lock Assembly.................................................................................................................16003
Rear Door Lock Assembly and Associated Parts........................................................................................16003
Removal.............................................................................................................................16003
Installation........................................................................................................................16004
Rear Outside Handle.....................................................................................................................16005
Rear Outside Handle and Associated Parts............................................................................................16005
Removal.............................................................................................................................16005
Installation........................................................................................................................16005
Tailgate Lock and Hatchgate Lock (LWB)..................................................................................................16006
Tailgate Lock, Hatchgate Lock and Associated Parts..................................................................................16006
Removal.............................................................................................................................16006
Installation........................................................................................................................16007
Tailgate Lock (SWB).....................................................................................................................16008
Tailgate Lock and Associated Parts..................................................................................................16008
Removal.............................................................................................................................16008
Installation........................................................................................................................16009
Key.....................................................................................................................................16010
Key Coding..........................................................................................................................16010
Key Styles..........................................................................................................................16010
Power Door Lock System..................................................................................................................16011
General Description.................................................................................................................16011
Door Lock Key Switch................................................................................................................16011
Front Door Lock Actuator............................................................................................................16011
Rear Door Lock Actuator.............................................................................................................16011
Tailgate Lock Actuator..............................................................................................................16011
Anti-Theft System.......................................................................................................................16011
General Description.................................................................................................................16011
Anti-Theft & Keyless Entry Control-ler..............................................................................................16011
Anti-Theft Indicator................................................................................................................16012
Anti-Theft Horn.....................................................................................................................16012
Engine Hood Switch..................................................................................................................16013
Anti-theft & Keyless Entry ControlUnit/Transmitter Replacement......................................................................16013
Keyless Entry System....................................................................................................................16014
ID Code Registration................................................................................................................16014
Main Data and Specifications............................................................................................................16018
8I SUNROOF/CONVERTIBLE TOP.................................................................................................................16019
Service Precaution......................................................................................................................16019
Sunroof Glass (LWB).....................................................................................................................16020
Sunroof Glass and Associated Parts..................................................................................................16020
Removal.............................................................................................................................16020
Installation........................................................................................................................16021
Sunroof Glass (SWB).....................................................................................................................16021
Sunroof Glass and Associated Parts..................................................................................................16021
Removal.............................................................................................................................16022
Installation........................................................................................................................16022
Sunroof Deflector (LWB).................................................................................................................16023
Removal.............................................................................................................................16023
Installation........................................................................................................................16023
Sunroof Deflector (SWB).................................................................................................................16024
Parts Location......................................................................................................................16024
Removal.............................................................................................................................16024
Installation........................................................................................................................16024
Sunshade (LWB)..........................................................................................................................16025
Disassembled View...................................................................................................................16025
Removal.............................................................................................................................16025
Installation........................................................................................................................16026
Sunroof Frame Complete Assembly (LWB)...................................................................................................16027
Sunroof Frame Complete Assembly and Associated Parts................................................................................16027
Removal.............................................................................................................................16027
Installation........................................................................................................................16028
Sunroof Switch..........................................................................................................................16028
Removal.............................................................................................................................16028
Installation........................................................................................................................16028
Sunroof Control Unit....................................................................................................................16029
Removal.............................................................................................................................16029
Installation........................................................................................................................16029
Safety Stop Switch......................................................................................................................16029
Removal.............................................................................................................................16029
Installation........................................................................................................................16029
Limit Switch............................................................................................................................16030
Removal.............................................................................................................................16030
Installation........................................................................................................................16030
Sunroof Motor...........................................................................................................................16030
Removal.............................................................................................................................16030
Installation........................................................................................................................16030
Soft Top Assembly.......................................................................................................................16031
Soft Top Assembly and Associated Parts..............................................................................................16031
Removal.............................................................................................................................16032
Installation........................................................................................................................16032
Resin Top Assembly......................................................................................................................16033
Resin Top Assembly and Associated Parts.............................................................................................16033
Removal.............................................................................................................................16033
Installation........................................................................................................................16034
Seat Belt Cross Bar Assembly............................................................................................................16035
Seat Belt Cross Bar Assembly and Associated Parts...................................................................................16035
Removal.............................................................................................................................16035
Installation........................................................................................................................16036
Main Data and Specifications............................................................................................................16037
8J EXTERIOR / INTERIOR TRIM.................................................................................................................16038
Service Precaution......................................................................................................................16039
Consoles................................................................................................................................16040
Consoles and Associated Parts.......................................................................................................16040
Removal.............................................................................................................................16040
Installation........................................................................................................................16040
Front Door Trim Panel...................................................................................................................16041
Front Door Trim Panel and Associated Parts..........................................................................................16041
Removal.............................................................................................................................16042
Installation........................................................................................................................16042
Rear Door Trim Panel....................................................................................................................16043
Rear Door Trim Panel and Associated Parts...........................................................................................16043
Removal.............................................................................................................................16044
Installation........................................................................................................................16044
Door Mirror Assembly....................................................................................................................16045
Removal.............................................................................................................................16045
Installation........................................................................................................................16045
Interior Trim Panels (LWB)..............................................................................................................16046
Interior Trim Panels and Associated Parts...........................................................................................16046
Removal.............................................................................................................................16046
Installation........................................................................................................................16048
Interior Trim Panels (SWB)..............................................................................................................16049
Interior Trim Panels and Associated Parts...........................................................................................16049
Removal.............................................................................................................................16049
Installation........................................................................................................................16050
Headlining (LWB)........................................................................................................................16051
Parts Location......................................................................................................................16051
Removal.............................................................................................................................16051
Installation........................................................................................................................16052
Headlining (SWB)........................................................................................................................16053
Parts Location......................................................................................................................16053
Removal.............................................................................................................................16054
Installation........................................................................................................................16055
Wheel Arch Protector (LWB)..............................................................................................................16056
Wheel Arch Protector and Associated Parts...........................................................................................16056
Removal.............................................................................................................................16056
Installation........................................................................................................................16056
Wheel Arch Protector (SWB)..............................................................................................................16057
Wheel Arch Protector and Associated Parts...........................................................................................16057
Removal.............................................................................................................................16057
Installation........................................................................................................................16057
Wheel Arch Molding (SWB)................................................................................................................16058
Wheel Arch Molding and Associated Parts.............................................................................................16058
Removal.............................................................................................................................16058
Installation........................................................................................................................16059
Wheel Arch Molding (LWB)................................................................................................................16060
Wheel Arch Molding and Associated Parts.............................................................................................16060
Removal.............................................................................................................................16060
Installation........................................................................................................................16061
Fuel Filler Door........................................................................................................................16061
Parts Location......................................................................................................................16061
Removal.............................................................................................................................16061
Installation........................................................................................................................16061
Roof Rail...............................................................................................................................16062
Parts Location......................................................................................................................16062
Removal.............................................................................................................................16062
Installation........................................................................................................................16062
License Plate Garnish...................................................................................................................16063
Parts Location......................................................................................................................16063
Removal.............................................................................................................................16063
Installation........................................................................................................................16064
Power Door Mirror System................................................................................................................16064
General Description.....................................................................................................................16064
Door Mirror Switch..................................................................................................................16064
Power Window System.....................................................................................................................16065
General Description.....................................................................................................................16065
Power Window Switch Driver Seat
Side................................................................................................16065
Power Window Motor..................................................................................................................16066
Main Data and Specifications........................................................................................................16067
Sec.9 RESTRAINTS................................................................................................................................16068
9A SEAT BELT SYSTEM........................................................................................................................16068
Service Precaution......................................................................................................................16068
Front Seat Belt (LWB)...................................................................................................................16069
Front Seat Belt and Associated Parts................................................................................................16069
Removal.............................................................................................................................16069
Inspection..........................................................................................................................16070
Installation........................................................................................................................16070
Front Seat Belt (SWB)...................................................................................................................16071
Front Seat Belt and Associated Parts................................................................................................16071
Removal.............................................................................................................................16071
Inspection..........................................................................................................................16073
Installation........................................................................................................................16073
Rear Seat Belt (LWB)....................................................................................................................16074
Rear Seat Belt and Associated Parts.................................................................................................16074
Removal.............................................................................................................................16074
Inspection..........................................................................................................................16075
Installation........................................................................................................................16076
Rear Seat Belt (SWB)....................................................................................................................16077
Rear Seat Belt and Associated Parts.................................................................................................16077
Removal.............................................................................................................................16077
Inspection..........................................................................................................................16079
Installation........................................................................................................................16079
Front Seat Buckle Assembly..............................................................................................................16080
Removal.............................................................................................................................16080
Installation........................................................................................................................16080
Rear Center Seat Belt / Buckle Assembly.................................................................................................16081
Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................16081
Removal.............................................................................................................................16081
Installation........................................................................................................................16081
Child Seat Tether Anchorage Bracket (Child Restraint)...................................................................................16082
Child Seat Tether Anchorage Bracket and Associated Parts............................................................................16082
Removal.............................................................................................................................16082
Installation........................................................................................................................16082
Child Seat Lower Anchorage Striker (LWB)................................................................................................16083
Child Seat Lower Anchorage Striker
and Associated Parts.............................................................................16083
Removal.............................................................................................................................16083
Installation........................................................................................................................16084
Main Data and Specifications............................................................................................................16085
9J SUPPLEMENTAL RESTRAINT SYSTEM (SRS).....................................................................................................16088
Service Precaution......................................................................................................................16088
General Description.....................................................................................................................16089
SRS Component and Wiring Location View..............................................................................................16091
Component Description...................................................................................................................16091
Definition..............................................................................................................................16094
Diagnosis...............................................................................................................................16095
SRS Connector Body Face Views...........................................................................................................16096
Repairs and Inspections Required After an Accident......................................................................................16096
On–Vehicle Service......................................................................................................................16097
Air Bag Assembly Handling /
Shipping / Scrapping........................................................................................16098
Special Tools...........................................................................................................................16113
Service Precaution......................................................................................................................16115
Sensing and Diagnostic Module (SDM).....................................................................................................16117
Service Precautions.................................................................................................................16117
Removal.............................................................................................................................16117
Installation........................................................................................................................16118
Driver Air Bag Assembly.................................................................................................................16119
Service Precautions.................................................................................................................16119
Removal.............................................................................................................................16119
Installation........................................................................................................................16119
Steering Wheel..........................................................................................................................16120
Service Precautions.................................................................................................................16120
Removal.............................................................................................................................16120
Installation........................................................................................................................16121
SRS Coil Assembly.......................................................................................................................16122
Service Precaution..................................................................................................................16122
Removal.............................................................................................................................16122
How to Disconnect the horn terminal.................................................................................................16124
How to Connect Horn Terminal........................................................................................................16124
Installation........................................................................................................................16125
Steering Column.........................................................................................................................16127
Service Precaution..................................................................................................................16127
Removal.............................................................................................................................16127
Installation........................................................................................................................16129
Passenger Air Bag Assembly..............................................................................................................16131
Service Precaution..................................................................................................................16131
Removal.............................................................................................................................16131
Installation........................................................................................................................16131
Main Data and Specifications............................................................................................................16132
SRS Air Bag System Inspection
Standards For Repair......................................................................................16133
9J1 SRS CONTROL SYSTEM......................................................................................................................16134
Service Precaution......................................................................................................................16134
Diagnostic Information..................................................................................................................16135
Plotting Snapshot Graph.................................................................................................................16140
Parts For Electrical Circuit............................................................................................................16143
System Schematic........................................................................................................................16144
SRS Diagnostic System Check.............................................................................................................16144
Chart A SDM Integrity Check.............................................................................................................16147
Chart B “AIR BAG” Warning Lamp Comes “ON” Steady........................................................................................16149
Chart C “AIR BAG” Warning Lamp Does Not Comes “ON” Steady...............................................................................16151
DTC 15 Passenger Deployment Loop Resistance High........................................................................................16154
DTC 16 Passenger Deployment Loop Resistance Low.........................................................................................16157
DTC 17 Passenger Deployment Loop Open...................................................................................................16160
DTC 18 Passenger Deployment Loop Short To Ground........................................................................................16162
DTC 19 Passenger Deployment Loop Short To Voltage.......................................................................................16164
DTC 21 Driver Deployment Loop Resistance High...........................................................................................16166
DTC 22 Driver Deployment Loop Resistance Low............................................................................................16169
DTC 24 Driver Deployment Loop Short To Ground...........................................................................................16172
DTC 25 Driver Deployment Loop Short To Voltage..........................................................................................16174
DTC 26 Driver Deployment Loop Open......................................................................................................16177
DTC 51 Deployment Event Commanded.......................................................................................................16180
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy
Reserves Out Of Range..................................................16182
DTC 61 Warning Lamp Circuit Failure.....................................................................................................16184
DTC 71 Internal SDM Fault...............................................................................................................16186
Sec.10 CONTROL SYSTEM...........................................................................................................................16188
10A CRUISE CONTROL SYSTEM...................................................................................................................16188
Service Precaution......................................................................................................................16188
General Description.....................................................................................................................16188
Brake Switch............................................................................................................................16189
Removal and Installation............................................................................................................16189
Adjustment..........................................................................................................................16189
Clutch Switch...........................................................................................................................16190
Removal and Installation............................................................................................................16190
Adjustment..........................................................................................................................16190
Powertrain Control Module (PCM).........................................................................................................16190
Removal and Installation............................................................................................................16190
Mode Switch.............................................................................................................................16190
Removal and Installation............................................................................................................16190
Cruise Control Main Switch..............................................................................................................16191
Removal.............................................................................................................................16191
Installation........................................................................................................................16191
Cruise Control Switch (Combination Switch)..............................................................................................16191
Removal and Installation............................................................................................................16191
Diagnosis...............................................................................................................................16192
(UA) RODEO SPORT....................................................................................................................................16193
Sec.0 GENERAL INFORMATION.......................................................................................................................16195
0A General Information......................................................................................................................16195
General Repair Instruction..............................................................................................................16195
Illustration Arrows.....................................................................................................................16196
Identification..........................................................................................................................16197
Theft Prevention Standard...............................................................................................................16200
Lifting Instructions....................................................................................................................16205
Standard Bolts Torque Specifications....................................................................................................16207
Abbreviations Charts....................................................................................................................16208
Service Parts Identification Plate......................................................................................................16209
0B Maintenance and Lubrication..............................................................................................................16210
Maintenance Schedule List...............................................................................................................16210
Explanation of Complete Vehicle Maintenance Schedule....................................................................................16214
Recommended Fluids and Lubricants...................................................................................................16217
Lubricant Viscosity Chart...............................................................................................................16218
Recommended Liquid Gasket...........................................................................................................16220
Recommended Thread Locking
Agents...................................................................................................16220
Maintenance Service Data................................................................................................................16221
Sec.1 HEATING, VENTILATION AND AIR CONDITIONING.................................................................................................16222
1A HVAC System..............................................................................................................................16222
Sec.2 STEERING..................................................................................................................................16224
2A POWER-ASSISTED STEERING SYSTEM...........................................................................................................16224
Service Precaution......................................................................................................................16225
Diagnosis...............................................................................................................................16225
General Description.....................................................................................................................16231
Power Steering System Test..............................................................................................................16233
Maintenance.............................................................................................................................16234
Fluid Level.............................................................................................................................16234
Bleeding The Power Steering System......................................................................................................16234
Bleeding Procedure......................................................................................................................16234
Flushing The Power Steering System......................................................................................................16234
Steering Wheel Free Play Inspection.....................................................................................................16235
Front End Alignment Inspection and
Adjustment...........................................................................................16235
Main Data and Specifications............................................................................................................16239
Special Tools.......................................................................................................................16240
Power Steering Unit.....................................................................................................................16241
Power Steering Unit and Associated Parts............................................................................................16241
Removal.............................................................................................................................16241
Installation (4×2 Model)............................................................................................................16242
Installation (4×4 Model)............................................................................................................16242
Power Steering Unit Disassembled View...............................................................................................16243
Disassembly.........................................................................................................................16243
Inspection and Repair...............................................................................................................16243
Reassembly..........................................................................................................................16243
Main Data and Specifications........................................................................................................16244
Special Tools...........................................................................................................................16244
Power Steering Pump.....................................................................................................................16245
Power Steering Pump and Associated Parts............................................................................................16245
Removal.............................................................................................................................16245
Installation........................................................................................................................16245
Power Steering Pump Disassembled View...............................................................................................16246
Disassembly.........................................................................................................................16246
Inspection and Repair...............................................................................................................16247
Reassembly..........................................................................................................................16247
Main Data and Specifications............................................................................................................16249
Transfer Gear Assembly..................................................................................................................16250
Transfer Gear Assembly and Associated Parts.........................................................................................16250
Removal.............................................................................................................................16250
Inspection and Repair...............................................................................................................16250
Installation........................................................................................................................16250
Supplemental Restraint System Steering Wheel & Column...................................................................................16251
Service Precaution..................................................................................................................16251
SRS Connectors......................................................................................................................16251
Inflator Module.........................................................................................................................16253
Inflator Module and Associated Parts................................................................................................16253
Removal.............................................................................................................................16253
Inspection and Repair...............................................................................................................16254
Installation........................................................................................................................16254
Steering Wheel..........................................................................................................................16255
Steering Wheel and Associated Parts.................................................................................................16255
Removal.............................................................................................................................16255
Installation........................................................................................................................16257
Combination Switch......................................................................................................................16258
Combination Switch and Associated Parts.............................................................................................16258
Removal.............................................................................................................................16258
Installation........................................................................................................................16260
Lock Cylinder...........................................................................................................................16262
Lock Cylinder and Associated Parts..................................................................................................16262
Removal.............................................................................................................................16262
Installation........................................................................................................................16264
System Inspection...................................................................................................................16265
Steering Column.........................................................................................................................16266
Steering Column and Associated Parts................................................................................................16266
Removal.............................................................................................................................16266
Installation........................................................................................................................16268
System Inspection...................................................................................................................16269
Supplemental Restraint System Steering Wheel & Column and
Associated Parts..............................................................16270
Main Data and Specifications............................................................................................................16270
Special Tools.......................................................................................................................16270
Sec.3 SUSPENSION................................................................................................................................16272
3C FRONT SUSPENSION.........................................................................................................................16272
Service Precaution......................................................................................................................16272
General Description.....................................................................................................................16273
Diagnosis...............................................................................................................................16273
Shock Absorber..........................................................................................................................16276
Shock Absorber and Associated Parts.................................................................................................16276
Removal.............................................................................................................................16276
Inspection and Repair...............................................................................................................16276
Installation........................................................................................................................16276
Stabilizer Bar..........................................................................................................................16277
Stabilizer Bar and Associated Parts.................................................................................................16277
Removal.............................................................................................................................16277
Inspection and Repair...............................................................................................................16277
Installation........................................................................................................................16277
Torsion Bar.............................................................................................................................16278
Torsion Bar and Associated Parts....................................................................................................16278
Removal.............................................................................................................................16278
Inspection and Repair...............................................................................................................16279
Installation........................................................................................................................16279
Knuckle.................................................................................................................................16281
Knuckle and Associated Parts........................................................................................................16281
Removal.............................................................................................................................16281
Inspection and Repair...............................................................................................................16282
Installation........................................................................................................................16282
Upper Control Arm.......................................................................................................................16284
Upper Control Arm and Associated Parts..............................................................................................16284
Removal.............................................................................................................................16284
Inspection and Repair...............................................................................................................16285
Installation........................................................................................................................16285
Lower Control Arm.......................................................................................................................16287
Lower Control Arm and Associated Parts..............................................................................................16287
Removal.............................................................................................................................16287
Inspection and Repair...............................................................................................................16288
Installation........................................................................................................................16289
Upper Ball Joint........................................................................................................................16290
Upper Ball Joint and Associated Parts...............................................................................................16290
Removal.............................................................................................................................16290
Inspection and Repair...............................................................................................................16291
Installation........................................................................................................................16291
Lower Ball Joint........................................................................................................................16292
Lower Ball Joint and Associated Parts...............................................................................................16292
Removal.............................................................................................................................16292
Inspection and Repair...............................................................................................................16293
Installation........................................................................................................................16293
Main Data and Specifications............................................................................................................16294
Special Tools...........................................................................................................................16295
3D REAR SUSPENSION..........................................................................................................................16296
Service Precaution......................................................................................................................16296
General Description.....................................................................................................................16296
Diagnosis...............................................................................................................................16297
Coil Spring.............................................................................................................................16300
Coil Spring and Associated Parts....................................................................................................16300
Removal.............................................................................................................................16300
Inspection and Repair...............................................................................................................16301
Installation........................................................................................................................16301
Shock Absorber..........................................................................................................................16302
Shock Absorber and Associated Parts.................................................................................................16302
Removal.............................................................................................................................16302
Inspection and Repair...............................................................................................................16302
Installation........................................................................................................................16302
Trailing Link...........................................................................................................................16303
Trailing Link and Associated Parts..................................................................................................16303
Removal.............................................................................................................................16303
Inspection and Repair...............................................................................................................16303
Installation........................................................................................................................16304
Upper Link..............................................................................................................................16305
Upper Link and Associated Parts.....................................................................................................16305
Removal.............................................................................................................................16305
Inspection and Repair...............................................................................................................16305
Installation........................................................................................................................16306
Lateral Rod.............................................................................................................................16307
Lateral Rod and Associated Parts....................................................................................................16307
Removal.............................................................................................................................16307
Inspection and Repair...............................................................................................................16307
Installation........................................................................................................................16308
Stabilizer Bar..........................................................................................................................16309
Stabilizer Bar and Associated Parts.................................................................................................16309
Removal.............................................................................................................................16309
Inspection and Repair...............................................................................................................16309
Installation........................................................................................................................16310
Main Data and Specifications............................................................................................................16310
Special Tools...........................................................................................................................16312
3E Wheel and Tire System....................................................................................................................16271
3F FINTELLIGENT SUSPENSION CONTROL..........................................................................................................16313
Service Precaution......................................................................................................................16314
General Description.....................................................................................................................16314
PIN ASSIGNMENT TABLE................................................................................................................16316
System Components...................................................................................................................16316
Control Unit........................................................................................................................16316
Actuator............................................................................................................................16316
Adjustable Damping Force Shock Absorber.............................................................................................16316
Warning Lamp and Mode Lamp..........................................................................................................16316
Vertical G-Sensor...................................................................................................................16317
Lateral G-Sensor....................................................................................................................16317
Acronyms and Abbreviations..........................................................................................................16317
General Diagnosis.......................................................................................................................16317
General Information.................................................................................................................16317
Service Precautions.................................................................................................................16317
Computer System Service Precautions.................................................................................................16317
General Service Precautions.........................................................................................................16317
Parts Handling......................................................................................................................16317
FLASHING CODES......................................................................................................................16318
CLEAR DTC...........................................................................................................................16319
INTERMITTENT CONDITIONS.............................................................................................................16320
BULB CHECK..........................................................................................................................16320
DTC CHECK...........................................................................................................................16320
Basic Diagnosis Flow................................................................................................................16321
Circuit Diagram.....................................................................................................................16322
Parts Location......................................................................................................................16325
Connector List......................................................................................................................16326
Diagnostic Trouble Code (DTC)
Identification........................................................................................16328
DTC2 Actuator Coil Over Current.........................................................................................................16329
Circuit Description.................................................................................................................16329
Diagnostic Aids.....................................................................................................................16329
DTC3 Actuator Coil/Position Sensor Open Circuit or Short................................................................................16331
Circuit Description.................................................................................................................16331
Diagnostic Aids.....................................................................................................................16331
DTC4 G-Sensor Open Circuit or Short.....................................................................................................16334
Circuit Description.................................................................................................................16334
Diagnostic Aids.....................................................................................................................16334
DTC5 Vehicle Speed Sensor Open Circuit or Short.........................................................................................16335
Circuit Description.................................................................................................................16335
Diagnostic Aids.....................................................................................................................16335
DTC6 Stop Lamp Switch Open Circuit or Short.............................................................................................16337
Circuit Description.................................................................................................................16337
Diagnostic Aids.....................................................................................................................16337
DTC7 Engine Speed Signal Open Circuit or Short..........................................................................................16339
Circuit Description.................................................................................................................16339
Diagnostic Aids.....................................................................................................................16339
DTC9 Control Unit Abnormality.......................................................................................................16340
Control Unit............................................................................................................................16344
Control Unit and Associated Parts...................................................................................................16344
Removal.................................................................................................................................16344
Installation............................................................................................................................16345
Front Actuator..........................................................................................................................16346
Front Actuator and Associated Parts.................................................................................................16346
Removal.................................................................................................................................16347
View B..............................................................................................................................16347
Inspection and Repair...................................................................................................................16347
Installation............................................................................................................................16347
Rear Shock Absorber.....................................................................................................................16348
Rear Shock Absorber and Associated Parts............................................................................................16348
Removal.................................................................................................................................16349
Inspection and Repair...................................................................................................................16349
Installation............................................................................................................................16349
Sec.4 DRIVELINE/AXLE............................................................................................................................16351
4A1 DIFFERENTIAL (FRONT)....................................................................................................................16351
Main Data And Specifications............................................................................................................16352
4A2 DIFFERENTIAL (REAR).....................................................................................................................16353
Main Data And Specifications............................................................................................................16354
4B Driveline Control System................................................................................................................16350
4C Drive Shaft System......................................................................................................................16355
Service Precaution......................................................................................................................16356
Front Propeller Shaft...................................................................................................................16357
General Description.................................................................................................................16357
Diagnosis of Propeller Shaft and
Universal Joint....................................................................................16359
Front Propeller Shaft and Associated Parts..........................................................................................16360
Removal.............................................................................................................................16360
Installation........................................................................................................................16360
Slip Joint Disassembly..............................................................................................................16361
Universal Joint Disassembly(Single Cardan Type).....................................................................................16362
Universal Joint Reassembly(Single
Cardan Type)......................................................................................16364
Slip Joint Reassembly...............................................................................................................16366
Main Data And Specifications........................................................................................................16367
Rear Propeller Shaft....................................................................................................................16368
General Description.................................................................................................................16368
Diagnosis of Propeller Shaft and
Universal Joint....................................................................................16370
Rear Propeller Shaft and Associated Parts...........................................................................................16371
Removal.............................................................................................................................16371
Installation........................................................................................................................16371
Slip Joint Disassembly (6VD1 Model Only)............................................................................................16372
Universal Joint Disassembly.........................................................................................................16373
Inspection..........................................................................................................................16375
Universal Joint Reassembly..........................................................................................................16376
Slip Joint Reassembly (6VD1 Model Only).............................................................................................16377
Main Data and Specifications........................................................................................................16378
4D Transfer Case...........................................................................................................................16350
Sec.5 BRAKE.....................................................................................................................................16379
5A Brake Control System.....................................................................................................................16379
5B Anti‐lock Brake System...................................................................................................................16379
5C Power‐assisted Brake System..............................................................................................................16379
5D Parking Brakes (4x4 Model)...............................................................................................................16379
5E Parking Brakes (4x2 Model)...............................................................................................................16379
Sec.6 ENGINE....................................................................................................................................16381
Y22SE 2.2L ENGINE...........................................................................................................................16381
6A Engine Mechanical...................................................................................................................16380
6B Engine Cooling......................................................................................................................16380
6C ENGINE FUEL (Y22SE 2.2L) For Short Wheel Base.......................................................................................16381
Service Precaution..................................................................................................................16381
General Description.................................................................................................................16382
Fuel Metering.......................................................................................................................16383
Fuel Filter.........................................................................................................................16384
Fuel Filter and Associated Parts................................................................................................16384
Removal.........................................................................................................................16384
Inspection......................................................................................................................16385
Installation....................................................................................................................16385
Inspection......................................................................................................................16385
In–Tank Fuel Filter.............................................................................................................16385
Fuel Pump Flow Test.............................................................................................................16385
Fuel Pump Relay.....................................................................................................................16386
General Description.............................................................................................................16386
Fuel Tank...........................................................................................................................16386
Fuel Tank and Associated Parts..................................................................................................16386
Removal.........................................................................................................................16387
Installation....................................................................................................................16387
Fuel Gauge Unit.....................................................................................................................16387
Removal and Installation........................................................................................................16387
Fuel Tube / Quick – Connector Fittings..............................................................................................16388
Precautions.....................................................................................................................16388
Cautions During Work............................................................................................................16388
Removal.........................................................................................................................16388
Reuse of Quick–Connector........................................................................................................16389
Assembling Advice...............................................................................................................16390
Fuel Filler Cap.....................................................................................................................16390
General Description.............................................................................................................16390
Inspection......................................................................................................................16390
Fuel Pump...........................................................................................................................16391
Fuel Pump and Associated Parts..................................................................................................16391
Removal.........................................................................................................................16391
Installation....................................................................................................................16392
Main Data and Specifications........................................................................................................16392
Special Tool....................................................................................................................16392
6D1 Engine Electrical...................................................................................................................16380
6D2 Ignition System.....................................................................................................................16380
6D3 Starting and Charging System........................................................................................................16380
6E Driveability and Emissions..........................................................................................................16380
6F Engine Exhaust......................................................................................................................16380
6G Engine Lubrication..................................................................................................................16380
6H Engine Speed Control System.........................................................................................................16380
6J Induction...........................................................................................................................16380
6VD1 3.2L ENGINE...........................................................................................................................16393
6A Engine Mechanical...................................................................................................................16380
6B Engine Cooling......................................................................................................................16380
6C ENGINE FUEL.........................................................................................................................16393
Service Precaution..................................................................................................................16393
General Description.................................................................................................................16394
Fuel Metering.......................................................................................................................16395
Fuel Filter.........................................................................................................................16396
Removal.........................................................................................................................16396
Inspection......................................................................................................................16396
Installation....................................................................................................................16397
Inspection......................................................................................................................16397
In‐Tank Fuel Filter.............................................................................................................16397
Fuel Pump Flow Test.............................................................................................................16397
Fuel Pump...........................................................................................................................16398
Fuel Pump and Associated Parts..................................................................................................16398
Removal.........................................................................................................................16398
Installation....................................................................................................................16399
Fuel Tube / Quick-Connector Fittings................................................................................................16400
Precautions.....................................................................................................................16400
Cautions During Work............................................................................................................16400
Removal.........................................................................................................................16400
Reuse of Quick–Connector........................................................................................................16401
Assembling Advice...............................................................................................................16402
Fuel Pump Relay.....................................................................................................................16402
General Description.............................................................................................................16402
Fuel Tank...........................................................................................................................16403
Fuel Tank and Associated Parts..................................................................................................16403
Removal.........................................................................................................................16403
Installation....................................................................................................................16404
Fuel Gauge Unit.....................................................................................................................16404
Removal and Installation........................................................................................................16404
Fuel Filler Cap.....................................................................................................................16404
General Description.............................................................................................................16404
Inspection......................................................................................................................16404
Main Data and Specifications........................................................................................................16405
Special Tool....................................................................................................................16405
6D1 Engine Electrical...................................................................................................................16380
6D2 Ignition System.....................................................................................................................16380
6D3 Starting and Charging System........................................................................................................16380
6E Driveability and Emissions..........................................................................................................16380
6F Engine Exhaust......................................................................................................................16380
6G Engine Lubrication..................................................................................................................16380
6H Engine Speed Control System.........................................................................................................16380
6J Induction...........................................................................................................................16380
Sec.7 TRANSMISSION..............................................................................................................................16406
7B Manual Transmission......................................................................................................................16406
7C Clutch...................................................................................................................................16406
Sec.8 BODY AND ACCESSORIES......................................................................................................................16407
8A Lighting System..........................................................................................................................16407
8B Wiper / Washer System....................................................................................................................16407
8C Entertainment............................................................................................................................16407
8D Wiring System............................................................................................................................16407
8E Meter and Gauge..........................................................................................................................16407
8F Body Structure...........................................................................................................................16407
8G Seats....................................................................................................................................16407
8H Security and Locks.......................................................................................................................16407
8I Sunroof / Convertible Top...............................................................................................................16407
8J Exterior / Interior Trim.................................................................................................................16407
Sec.9 RESTRAINTS................................................................................................................................16408
9A Seat Belt System........................................................................................................................16408
9J Supplemental Restraint System (Air Bag System) .........................................................................................16408
9J1 Restraint Control System................................................................................................................16408
Sec.10 CONTROL SYSTEM...........................................................................................................................16409
10A Cruise Control System...................................................................................................................16409
2002 MODEL.............................................................................................................................................. 2
(UP) AXIOM..........................................................................................................................................16410
Sec.0 GENERAL INFORMATION.....................................................................................................................16411
0A General Information......................................................................................................................16411
General Repair Instruction..............................................................................................................16411
Illustration Arrows.....................................................................................................................16412
Identification..........................................................................................................................16413
Theft Prevention Standard...............................................................................................................16415
Lifting Instructions....................................................................................................................16419
Standard Bolts Torque Specifications....................................................................................................16421
Abbreviations Charts....................................................................................................................16422
Service Parts Identification Plate......................................................................................................16423
0B Maintenance and Lubrication..............................................................................................................16424
Maintenance Schedule List...............................................................................................................16424
Explanation of Complete Vehicle Maintenance Schedule....................................................................................16428
Recommended Fluids and Lubricants...................................................................................................16431
Lubricant Viscosity Chart...............................................................................................................16432
Recommended Liquid Gasket...........................................................................................................16434
Recommended Thread Locking Agents...................................................................................................16434
Maintenance Service Data................................................................................................................16435
Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................................................16436
1A HVAC SYSTEMS.............................................................................................................................16436
Service Precaution......................................................................................................................16438
Heating and Ventilation System..........................................................................................................16438
General Description.....................................................................................................................16438
Heater Unit.............................................................................................................................16441
Heater Unit and Associated Parts....................................................................................................16441
Removal.............................................................................................................................16441
Installation........................................................................................................................16441
Heater Core and / or Mode Door..........................................................................................................16442
Disassembled View...................................................................................................................16442
Removal.............................................................................................................................16443
Inspection..........................................................................................................................16443
Installation........................................................................................................................16443
Heater Mode Control Link Unit...........................................................................................................16444
Disassembled View...................................................................................................................16444
Removal.............................................................................................................................16444
Installation........................................................................................................................16445
Heater Temperature Control Link Unit....................................................................................................16446
Disassembled View...................................................................................................................16446
Removal.............................................................................................................................16446
Installation........................................................................................................................16446
Blower Assembly.........................................................................................................................16447
Blower Assembly and Associated Parts................................................................................................16447
Removal.............................................................................................................................16447
Installation........................................................................................................................16447
Blower Link Unit and / or Mode door.....................................................................................................16448
Disassembled View...................................................................................................................16448
Removal.............................................................................................................................16448
Installation........................................................................................................................16449
Blower Motor............................................................................................................................16450
Blower Motor and Associated Parts...................................................................................................16450
Removal.............................................................................................................................16450
Installation........................................................................................................................16450
Rear Heater Duct, Defroster Nozzle and Ventilation Duct.................................................................................16451
Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts...........................................................16451
Removal.............................................................................................................................16451
Installation........................................................................................................................16452
Air Conditioning System.................................................................................................................16453
General Description.....................................................................................................................16453
Diagnosis...............................................................................................................................16459
Air Conditioning System.................................................................................................................16466
Individual Inspection...................................................................................................................16466
General Repair Procedure............................................................................................................16466
Leak Check..........................................................................................................................16468
Compressor Assembly.....................................................................................................................16473
Compressor Assembly and Associated Parts (6VE1).....................................................................................16473
Removal.............................................................................................................................16473
Installation........................................................................................................................16474
New Compressor Installation.........................................................................................................16474
Condenser Assembly......................................................................................................................16475
Condenser Assembly and Associated Parts.............................................................................................16475
Removal.............................................................................................................................16475
Installation........................................................................................................................16476
Condenser Fan Motor.....................................................................................................................16477
Condenser Fan Motor and Associated Parts............................................................................................16477
Removal.............................................................................................................................16477
Installation........................................................................................................................16477
Receiver / Drier........................................................................................................................16478
Receiver / Drier and Associated Parts...............................................................................................16478
Removal.............................................................................................................................16478
Installation........................................................................................................................16478
Pressure Switch.........................................................................................................................16479
Pressure Switch and Associated Parts................................................................................................16479
Removal.............................................................................................................................16479
Installation........................................................................................................................16479
Evaporator Assembly.....................................................................................................................16480
Evaporator Assembly and Associated Parts............................................................................................16480
Removal.............................................................................................................................16480
Installation........................................................................................................................16481
Duct Sensor, Evaporator Core and/or Expansion Valve.....................................................................................16482
Disassembled View...................................................................................................................16482
Removal.............................................................................................................................16482
Installation........................................................................................................................16483
Refrigerant Line........................................................................................................................16484
Refrigerant Line and Associated Parts...............................................................................................16484
Removal.............................................................................................................................16484
Installation........................................................................................................................16485
Main Data And Specifications............................................................................................................16486
Compressor..............................................................................................................................16488
Service Precaution..................................................................................................................16488
General Description.................................................................................................................16488
Diagnosis...........................................................................................................................16489
Magnetic Clutch Assembly (DKV-14G Type).................................................................................................16490
Parts Location View.................................................................................................................16490
Removal.............................................................................................................................16490
Inspection and Repair...............................................................................................................16492
Installation........................................................................................................................16492
Compressor Oil..........................................................................................................................16494
Oil Specification...................................................................................................................16494
Handling of Oil.....................................................................................................................16494
Compressor Oil Check................................................................................................................16494
Checking and Adjusting Oil Quantity for Used Compressor.............................................................................16494
Checking and Adjusting for Compressor Replacement...................................................................................16495
Contamination of Compressor Oil.....................................................................................................16495
Oil Return Operation................................................................................................................16495
Replacement of Component Parts......................................................................................................16495
Main Data and Specifications............................................................................................................16496
Special Tools.......................................................................................................................16498
Automatic Air Conditioning System.......................................................................................................16499
General Description.................................................................................................................16499
Automatic Air Conditioner Parts Configuration.......................................................................................16499
Circuit Diagram.....................................................................................................................16500
Functions and Features..............................................................................................................16505
Automatic Air Conditioner Block Diagram.............................................................................................16506
Control Panel Layout................................................................................................................16507
Air Control Functions...............................................................................................................16508
Control Panel Switch Operation......................................................................................................16509
Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System...................................16512
Overview of Automatic Control of Automatic Air Conditioner..........................................................................16516
Automatic Air Conditioning System...................................................................................................16517
Troubleshooting.........................................................................................................................16521
Troubleshooting, Its Overview and Procedures........................................................................................16521
Auto Air Conditioner Control Unit Power Supply Diagnosis............................................................................16522
Performance and Movement checklist for Automatic Air Conditioner Related Parts......................................................16524
Troubleshooting With Self-Diagnosis Function........................................................................................16526
Inspection By Failed Location...........................................................................................................16532
Inspection of the Sensors...........................................................................................................16532
Inspection of the Intake Actuator System............................................................................................16536
Inspection of the Mix Actuator System...............................................................................................16539
Inspection of the Mode Actuator System..............................................................................................16542
Inspection of the Fan Motor System..................................................................................................16545
Inspection of the Magnetic Clutch System............................................................................................16550
Individual Inspection...............................................................................................................16553
On-Vehicle Service......................................................................................................................16556
Power Transistor....................................................................................................................16556
Removal.............................................................................................................................16556
Installation........................................................................................................................16556
Automatic Heater/Air Conditioner Control Unit.......................................................................................16556
Removal.............................................................................................................................16556
Installation........................................................................................................................16556
In Car Sensor.......................................................................................................................16557
Removal.............................................................................................................................16557
Installation........................................................................................................................16557
Ambient Sensor......................................................................................................................16557
Removal.............................................................................................................................16557
Installation........................................................................................................................16557
Sun Sensor..........................................................................................................................16558
Removal.............................................................................................................................16558
Installation........................................................................................................................16558
Duct Sensor.........................................................................................................................16558
Removal.............................................................................................................................16558
Installation........................................................................................................................16558
Mode Actuator.......................................................................................................................16559
Removal.............................................................................................................................16559
Installation........................................................................................................................16559
Mix Actuator........................................................................................................................16559
Removal.............................................................................................................................16559
Installation........................................................................................................................16559
Intake Actuator.....................................................................................................................16560
Removal.............................................................................................................................16560
Installation........................................................................................................................16560
Sec.2 STEERING................................................................................................................................16561
2A POWER-ASSISTED STEERING SYSTEM...........................................................................................................16561
Service Precaution......................................................................................................................16562
Diagnosis...............................................................................................................................16562
General Description.....................................................................................................................16568
Power Steering System Test..............................................................................................................16570
Maintenance.............................................................................................................................16571
Fluid Level.............................................................................................................................16571
Bleeding The Power Steering System......................................................................................................16571
Bleeding Procedure......................................................................................................................16571
Flushing The Power Steering System......................................................................................................16571
Steering Wheel Free Play Inspection.....................................................................................................16572
Front End Alignment Inspection and Adjustment...........................................................................................16572
Main Data and Specifications............................................................................................................16576
Special Tools...........................................................................................................................16577
Power Steering Unit.....................................................................................................................16578
Power Steering Unit and Associated Parts............................................................................................16578
Removal.............................................................................................................................16578
Installation (4×2 Model)............................................................................................................16579
Installation (4×4 Model)............................................................................................................16579
Power Steering Unit Disassembled View...............................................................................................16580
Disassembly.........................................................................................................................16581
Inspection and Repair...............................................................................................................16581
Reassembly..........................................................................................................................16581
Main Data and Specifications........................................................................................................16582
Special Tools...........................................................................................................................16582
Power Steering Pump.....................................................................................................................16583
Power Steering Pump and Associated Parts............................................................................................16583
Removal.............................................................................................................................16583
Installation........................................................................................................................16583
Power Steering Pump Disassembled View...............................................................................................16584
Disassembly.........................................................................................................................16584
Inspection and Repair...............................................................................................................16585
Reassembly..........................................................................................................................16585
Main Data and Specifications........................................................................................................16587
Transfer Gear Assembly..................................................................................................................16588
Transfer Gear Assembly and Associated Parts.........................................................................................16588
Removal.............................................................................................................................16588
Inspection and Repair...............................................................................................................16588
Installation........................................................................................................................16588
Supplemental Restraint System Steering Wheel & Column...................................................................................16589
Service Precaution..................................................................................................................16589
SRS Connectors......................................................................................................................16589
Inflator Module.........................................................................................................................16591
Inflator Module and Associated Parts................................................................................................16591
Removal.............................................................................................................................16591
Inspection and Repair...............................................................................................................16592
Installation........................................................................................................................16592
Steering Wheel..........................................................................................................................16593
Steering Wheel and Associated Parts.................................................................................................16593
Removal.............................................................................................................................16593
Installation........................................................................................................................16595
Combination Switch......................................................................................................................16596
Combination Switch and Associated Parts.............................................................................................16596
Removal.............................................................................................................................16596
Installation........................................................................................................................16598
Lock Cylinder...........................................................................................................................16600
Lock Cylinder and Associated Parts..................................................................................................16600
Removal.............................................................................................................................16600
Installation........................................................................................................................16602
System Inspection...................................................................................................................16603
Steering Column.........................................................................................................................16604
Steering Column and Associated Parts................................................................................................16604
Removal.............................................................................................................................16604
Inspection..........................................................................................................................16606
Installation........................................................................................................................16608
System Inspection.......................................................................................................................16609
Supplemental Restraint System Steering Wheel & Column and Associated Parts..............................................................16610
Main Data and Specifications........................................................................................................16610
Special Tools.......................................................................................................................16610
Sec.3 SUSPENSION..............................................................................................................................16611
3C FRONT SUSPENSION.........................................................................................................................16611
Service Precaution......................................................................................................................16611
General Description.....................................................................................................................16612
Diagnosis...............................................................................................................................16612
Shock Absorber..........................................................................................................................16615
Shock Absorber and Associated Parts.................................................................................................16615
Removal.............................................................................................................................16615
Inspection and Repair...............................................................................................................16615
Installation........................................................................................................................16615
Stabilizer Bar..........................................................................................................................16616
Stabilizer Bar and Associated Parts.................................................................................................16616
Removal.............................................................................................................................16616
Inspection and Repair...............................................................................................................16616
Installation........................................................................................................................16616
Torsion Bar.............................................................................................................................16617
Torsion Bar and Associated Parts....................................................................................................16617
Removal.............................................................................................................................16617
Inspection and Repair...............................................................................................................16618
Installation........................................................................................................................16618
Knuckle.................................................................................................................................16620
Knuckle and Associated Parts........................................................................................................16620
Removal.............................................................................................................................16620
Inspection and Repair...............................................................................................................16621
Installation........................................................................................................................16621
Upper Control Arm.......................................................................................................................16623
Upper Control Arm and Associated Parts..............................................................................................16623
Removal.............................................................................................................................16623
Inspection and Repair...............................................................................................................16624
Installation........................................................................................................................16624
Lower Control Arm.......................................................................................................................16626
Lower Control Arm and Associated Parts..............................................................................................16626
Removal.............................................................................................................................16626
Inspection and Repair...............................................................................................................16627
Installation........................................................................................................................16628
Upper Ball Joint........................................................................................................................16629
Upper Ball Joint and Associated Parts...............................................................................................16629
Removal.............................................................................................................................16629
Inspection and Repair...............................................................................................................16630
Installation........................................................................................................................16630
Lower Ball Joint........................................................................................................................16631
Lower Ball Joint and Associated Parts...............................................................................................16631
Removal.............................................................................................................................16631
Inspection and Repair...............................................................................................................16632
Installation........................................................................................................................16632
Main Data and Specifications............................................................................................................16633
Special Tools...........................................................................................................................16635
3D REAR SUSPENSION..........................................................................................................................16636
Service Precaution......................................................................................................................16636
General Description.....................................................................................................................16636
Diagnosis...............................................................................................................................16637
Coil Spring.............................................................................................................................16640
Coil Spring and Associated Parts....................................................................................................16640
Removal.............................................................................................................................16640
Inspection and Repair...............................................................................................................16641
Installation........................................................................................................................16641
Shock Absorber..........................................................................................................................16642
Shock Absorber and Associated Parts.................................................................................................16642
Removal.............................................................................................................................16642
Inspection and Repair...............................................................................................................16642
Installation........................................................................................................................16642
Trailing Link...........................................................................................................................16643
Trailing Link and Associated Parts..................................................................................................16643
Removal.............................................................................................................................16643
Inspection and Repair...............................................................................................................16643
Installation........................................................................................................................16644
Upper Link..............................................................................................................................16645
Upper Link and Associated Parts.....................................................................................................16645
Removal.............................................................................................................................16645
Inspection and Repair...............................................................................................................16645
Installation........................................................................................................................16646
Lateral Rod.............................................................................................................................16647
Lateral Rod and Associated Parts....................................................................................................16647
Removal.............................................................................................................................16647
Inspection and Repair...............................................................................................................16647
Installation........................................................................................................................16648
Stabilizer Bar..........................................................................................................................16649
Stabilizer Bar and Associated Parts.................................................................................................16649
Removal.............................................................................................................................16649
Inspection and Repair...............................................................................................................16649
Installation........................................................................................................................16650
Main Data and Specifications............................................................................................................16651
Special Tools...........................................................................................................................16653
3E WHEEL AND TIRE SYSTEM....................................................................................................................16672
Service Precaution......................................................................................................................16672
General Description.....................................................................................................................16673
Diagnosis...............................................................................................................................16674
Wheel...................................................................................................................................16682
Wheel and Associated Parts..........................................................................................................16682
Removal.............................................................................................................................16682
Installation........................................................................................................................16682
Tire....................................................................................................................................16683
Tire Replacement....................................................................................................................16683
General Balance Procedure...............................................................................................................16683
Balancing Wheel and Tire................................................................................................................16684
Main Data and Specifications............................................................................................................16685
3F INTELLIGENT SUSPENSION CONTROL...........................................................................................................16686
Service Precaution......................................................................................................................16687
General Description.....................................................................................................................16687
PIN ASSIGNMENT TABLE................................................................................................................16689
System Components...................................................................................................................16689
Control Unit........................................................................................................................16689
Actuator............................................................................................................................16689
Adjustable Damping Force Shock Absorber.............................................................................................16689
Warning Lamp........................................................................................................................16689
Vertical G-Sensor...................................................................................................................16690
Lateral G-Sensor....................................................................................................................16690
Acronyms and Abbreviations..........................................................................................................16690
General Diagnosis.......................................................................................................................16690
General Information.................................................................................................................16690
Service Precautions.................................................................................................................16690
Computer System Service Precautions.................................................................................................16690
General Service Precautions.........................................................................................................16690
Parts Handling......................................................................................................................16690
FLASHING CODES......................................................................................................................16691
CLEAR DTC...........................................................................................................................16692
INTERMITTENT CONDITIONS.............................................................................................................16693
BULB CHECK..........................................................................................................................16693
DTC CHECK...........................................................................................................................16693
Connector List......................................................................................................................16699
Diagnostic Trouble Code (DTC) Identification........................................................................................16701
DTC2 Actuator Coil Over Current.........................................................................................................16702
Circuit Description.................................................................................................................16702
Diagnostic Aids.....................................................................................................................16702
DTC3 Actuator Coil/Position Sensor Open Circuit or Short................................................................................16704
Circuit Description.................................................................................................................16704
Diagnostic Aids.....................................................................................................................16704
DTC4 G-Sensor Open Circuit or Short.....................................................................................................16707
Circuit Description.................................................................................................................16707
Diagnostic Aids.....................................................................................................................16707
DTC5 Vehicle Speed Sensor Open Circuit or Short.........................................................................................16708
Circuit Description.................................................................................................................16708
Diagnostic Aids.....................................................................................................................16708
DTC6 Stop Lamp Switch Open Circuit or Short.............................................................................................16710
Circuit Description.................................................................................................................16710
Diagnostic Aids.....................................................................................................................16710
DTC7 Engine Speed Signal Open Circuit or Short..........................................................................................16712
Circuit Description.................................................................................................................16712
Diagnostic Aids.....................................................................................................................16712
DTC9 Control Unit Abnormality...........................................................................................................16713
Control Unit............................................................................................................................16717
Removal.................................................................................................................................16718
Installation............................................................................................................................16718
Front Actuator..........................................................................................................................16719
Removal.................................................................................................................................16720
Inspection and Repair...................................................................................................................16720
Installation............................................................................................................................16720
Rear Shock Absorber.....................................................................................................................16721
Rear Shock Absorber.....................................................................................................................16721
Removal.................................................................................................................................16722
Inspection and Repair...................................................................................................................16722
Installation............................................................................................................................16722
Sec.4 DRIVELINE/AXLE..........................................................................................................................16723
4A1 Differential (Front)....................................................................................................................16723
Service Precaution......................................................................................................................16723
Front Drive Axle........................................................................................................................16724
Diagnosis...............................................................................................................................16724
Pinion Shaft Oil Seal...................................................................................................................16725
Pinion Shaft Oil Seal and Associated Parts..........................................................................................16725
Removal.............................................................................................................................16725
Inspection and Repair...............................................................................................................16726
Installation........................................................................................................................16726
Front Drive Axle Assembly...............................................................................................................16727
Front Drive Axle Assembly and Associated Parts......................................................................................16727
Removal.............................................................................................................................16728
Installation........................................................................................................................16728
Differential Assembly...................................................................................................................16730
Disassembled View...................................................................................................................16730
Disassembly.........................................................................................................................16731
Reassembly..........................................................................................................................16733
Differential Cage Assembly..............................................................................................................16742
Disassembled View...................................................................................................................16742
Disassembly.........................................................................................................................16742
Inspection and Repair...............................................................................................................16743
Reassembly..........................................................................................................................16743
Main Data and Specifications........................................................................................................16745
Special Tools.......................................................................................................................16747
4A2 Differential (Rear).....................................................................................................................16749
Service Precaution......................................................................................................................16749
General Description.....................................................................................................................16750
Diagnosis...............................................................................................................................16751
Axle Housing............................................................................................................................16753
Axle Housing and Associated Parts...................................................................................................16753
Removal.............................................................................................................................16753
Installation........................................................................................................................16755
Axle Shaft, Oil Seal and Bearing........................................................................................................16755
Axle Shaft and Associated Parts.....................................................................................................16755
Removal.............................................................................................................................16756
Inspection..........................................................................................................................16756
Installation........................................................................................................................16756
Pinion Oil Seal.........................................................................................................................16758
Pinion Oil Seal and Associated Parts................................................................................................16758
Removal.............................................................................................................................16758
Inspection and Repair...............................................................................................................16759
Installation........................................................................................................................16759
Differential Assembly...................................................................................................................16761
Disassembled View...................................................................................................................16761
Inspecting the Axle Before Disassembly..............................................................................................16762
Disassembly.........................................................................................................................16762
Inspection and Repair...............................................................................................................16764
Reassembly..........................................................................................................................16764
Side Bearing Preload Adjustment.....................................................................................................16768
Pinion Installation.................................................................................................................16769
Determination of Backlash & Preload Shims...........................................................................................16770
Backlash Adjustment.................................................................................................................16771
Gear Tooth Pattern Check............................................................................................................16771
Adjustments Affecting Tooth Contact.................................................................................................16772
Differential Case Assembly..............................................................................................................16773
Disassembled View...................................................................................................................16773
Disassembly.........................................................................................................................16774
Inspection and Repair...............................................................................................................16774
Reassembly..........................................................................................................................16774
Limited Slip Differential Assembly......................................................................................................16775
Disassembled View...................................................................................................................16775
Disassembly.........................................................................................................................16775
Inspection and Repair...............................................................................................................16777
Reassembly..........................................................................................................................16777
Main Data And Specifications............................................................................................................16779
Special Tools...........................................................................................................................16780
4B1 DRIVELINE CONTROL SYSTEM................................................................................................................16782
Service Precaution......................................................................................................................16782
Shift On The Fly System.................................................................................................................16783
Outline of Shift on The Fly System......................................................................................................16783
Functions of Indicator Lamp.............................................................................................................16785
Shift On The Fly Electrical Equipment...................................................................................................16786
Axle Shaft Connection and Disconnection.................................................................................................16786
Shift On The Fly Controller.............................................................................................................16788
Shift On The Fly Controller and Associated Parts....................................................................................16788
Removal.............................................................................................................................16788
Installation........................................................................................................................16788
4B2 DRIVELINE CONTROL SYSTEM (TOD)..........................................................................................................16789
Service Precaution......................................................................................................................16789
General Description.....................................................................................................................16790
Transfer Position and Drive Mode....................................................................................................16790
TOD Control.........................................................................................................................16791
TOD Indicator Control...............................................................................................................16791
Abbreviations.......................................................................................................................16791
System Components.......................................................................................................................16792
Parts Location......................................................................................................................16792
Front and Rear Speed Sensors........................................................................................................16793
Electromagnetic Coil................................................................................................................16793
Multi Plate Disk Clutch Pack........................................................................................................16793
Mechanical Lock Sleeve..............................................................................................................16793
High-Low Planetary Gear Set.........................................................................................................16794
4H and 4L Switch....................................................................................................................16794
Transfer Connector (12-pin type)....................................................................................................16794
Transfer Connector (8-pin type).....................................................................................................16794
TOD Indicator Lamps (on the instrument panel).......................................................................................16795
Check Lamp..........................................................................................................................16795
TOD ECU.............................................................................................................................16796
High-Low Shift Motor................................................................................................................16797
Motor Position and Encoder Position Code............................................................................................16798
Encode Position Plate...............................................................................................................16798
Shift High Range and Low Range......................................................................................................16798
Functions of TOD Switch and Indicator Lamp..............................................................................................16799
TOD Switch and Indication of Drive Mode.............................................................................................16799
Check Lamp..........................................................................................................................16801
Diagnosis...............................................................................................................................16802
General Information Diagnosis.......................................................................................................16802
Self-diagnosis......................................................................................................................16802
Precautions on Diagnosis............................................................................................................16804
Basic Diagnostic Flow Chart.............................................................................................................16806
Parts Location..........................................................................................................................16807
Circuit Diagram.........................................................................................................................16808
Connector List..........................................................................................................................16812
Checking Failed Pin.....................................................................................................................16814
Connector Pin Assignment............................................................................................................16814
Reference...........................................................................................................................16816
Checking Failed TOD Control Unit Pin....................................................................................................16818
Tech 2 Scan Tool....................................................................................................................16820
Getting Started.....................................................................................................................16821
Operating Procedure.................................................................................................................16821
Diagnostic Trouble Codes................................................................................................................16823
Diagnosis from Trouble Codes............................................................................................................16824
Trouble Diagnosis Depending on The Status of TOD Indicator..............................................................................16855
Diagnosis from Symptom..................................................................................................................16890
4C DRIVE SHAFT SYSTEM.......................................................................................................................16907
Service Precaution......................................................................................................................16907
General Description.....................................................................................................................16908
Diagnosis...............................................................................................................................16908
Front Hub and Disc (2WD Model)..........................................................................................................16909
Disassembled View...................................................................................................................16909
Disassembly.........................................................................................................................16909
Inspection and Repair...............................................................................................................16910
Reassembly..........................................................................................................................16911
Front Hub and Disc (4WD Model)..........................................................................................................16914
Disassembled View...................................................................................................................16914
Disassembly.........................................................................................................................16914
Inspection and Repair...............................................................................................................16916
Reassembly..........................................................................................................................16916
Front Drive Shaft Joint.................................................................................................................16919
Front Drive Shaft Joints Replacement................................................................................................16919
Front Axle Drive Shaft..................................................................................................................16920
Front Axle Drive Shaft and Associated Parts.........................................................................................16920
Disassembly.........................................................................................................................16921
Inspection And Repair...............................................................................................................16922
Bushing Replacement.................................................................................................................16922
Reassembly..........................................................................................................................16923
Shift On The Fly System.................................................................................................................16925
Shift On The Fly System and Associated Parts........................................................................................16925
Disassembly.........................................................................................................................16926
Inspection And Repair...............................................................................................................16927
Reassembly..........................................................................................................................16929
Main Data and Specifications........................................................................................................16932
Special Tools.......................................................................................................................16934
Propeller Shaft.........................................................................................................................16935
General Description.................................................................................................................16935
Front Propeller Shaft...................................................................................................................16936
General Description.................................................................................................................16936
Front Propeller Shaft and Associated Parts..........................................................................................16937
Removal.............................................................................................................................16937
Installation........................................................................................................................16938
Main Data and Specifications........................................................................................................16941
Rear Propeller Shaft....................................................................................................................16942
Rear Propeller Shaft and Associated Parts...........................................................................................16942
Removal.............................................................................................................................16942
Installation........................................................................................................................16942
Slip Joint Disassembly..............................................................................................................16943
Universal Joint Disassembly.........................................................................................................16944
Inspection..........................................................................................................................16946
Universal Joint Reassembly..........................................................................................................16947
Slip Joint Reassembly...............................................................................................................16948
Main Data and Specifications........................................................................................................16949
4D2 TRANSFER CASE (TOD).....................................................................................................................16993
Service Precaution......................................................................................................................16993
General Description.....................................................................................................................16994
Removal and Installation of Tfansfer Case Assembly......................................................................................16995
Removal.............................................................................................................................16996
Installation........................................................................................................................16996
Transfer Rear Oil Seal..................................................................................................................16998
Removal.............................................................................................................................16998
Installation........................................................................................................................16998
TOD Control Unit........................................................................................................................17000
Removal.............................................................................................................................17000
Installation........................................................................................................................17000
Unit Repair.............................................................................................................................17001
Disassembly and Reassembly of Major Components......................................................................................17001
Disassembly.........................................................................................................................17002
Reassembly..........................................................................................................................17002
Transfer Cover Assembly.................................................................................................................17005
Disassembly.........................................................................................................................17005
Inspection and Repair...............................................................................................................17006
Reassembly..........................................................................................................................17007
Clutch Pack and Clutch Cam (Transfer Case Assembly).....................................................................................17008
Disassembly.........................................................................................................................17008
Reassembly..........................................................................................................................17010
Chain, Sprocket and Mechanical Lock (Transfer Case Assembly)............................................................................17012
Disassembly.........................................................................................................................17013
Reassembly..........................................................................................................................17014
Transfer Case Assembly..................................................................................................................17016
Disassembly.........................................................................................................................17016
Reassembly..........................................................................................................................17018
Inspection and Repair (Transfer Case Assembly)......................................................................................17020
Main Data and Specification.............................................................................................................17024
General Specification...............................................................................................................17024
Torque Specifications...............................................................................................................17025
Torque Specifications (Cont’d)......................................................................................................17026
Torque Specifications (Cont’d)......................................................................................................17027
Special Tools...........................................................................................................................17028
Sec.5 BRAKES..................................................................................................................................17029
5A Brake Control System....................................................................................................................17029
Service Precaution......................................................................................................................17030
General Description.....................................................................................................................17031
Functional Description..............................................................................................................17032
System Components...................................................................................................................17038
Electronic Hydraulic Control Unit (EHCU)............................................................................................17038
ABS Warning Light...................................................................................................................17038
Wheel Speed Sensor..................................................................................................................17038
G-Sensor............................................................................................................................17038
Normal and Anti-lock Braking........................................................................................................17038
Brake Pedal Travel..................................................................................................................17038
Acronyms and Abbreviations..........................................................................................................17039
General Diagnosis.......................................................................................................................17039
General Information.................................................................................................................17039
ABS Service Precautions.............................................................................................................17039
Computer System Service Precautions.................................................................................................17039
General Service Precautions.........................................................................................................17039
Note on Intermittents...............................................................................................................17039
Test Driving ABS Complaint Vehicles.................................................................................................17040
“ABS” Warning Light.................................................................................................................17040
Normal Operation....................................................................................................................17040
Tech 2 Scan Tool....................................................................................................................17041
DATA LIST...........................................................................................................................17044
ACTUATOR TEST.......................................................................................................................17045
Tech 2 Service Bleed................................................................................................................17049
Basic Diagnostic Flow Chart.........................................................................................................17050
Basic Inspection Procedure..........................................................................................................17051
EHCU Connector Pin-out Checks...........................................................................................................17052
Circuit Diagram.....................................................................................................................17053
Connector List......................................................................................................................17056
Part Location.......................................................................................................................17057
Symptom Diagnosis.......................................................................................................................17058
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate......................................................................17058
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................17059
Chart A-2 Uneven Braking Occurs While ABS Works.....................................................................................17059
Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2).......................................................................17059
Chart A-3, TA-3 The Wheels Are Locked...............................................................................................17060
Chart A-4 Brake Pedal Feed Is Abnormal..............................................................................................17060
Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................17061
Diagnostic Trouble Codes................................................................................................................17062
Diagnosis By “ABS” Warning Light Illumination Pattern...................................................................................17064
Diagnostic Trouble Codes (DTCs).....................................................................................................17065
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................17067
Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial communications)........................................17067
Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial communications))...................................17068
Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications))..................................................17068
Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications)).............................................17068
Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications))..............................................17069
Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications)).................................................17069
Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial communications)), 4WD State Input Sig........17070
Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial communications))............................................17070
Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash out) / C0265, C0266 (Serial communications)).....................................17071
Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial communications))...........................17071
Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial communications))................................17071
Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash out) / C0241, C0243 (Serial communications))...........................17072
Chart B-14 FR Dump Solenoid Coil Failure (DTC 44(Flash out) / C0242, C0244 (Serial communications)).................................17072
Chart B-15 Rear Isolation Solenoid Coil Failure (DTC 45 (Flash out) / C0251, C0253 (Serial communications)).........................17072
Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash out) / C0252, C0254 (Serial communications))..............................17073
Chart B-17 FL Speed Sensor Open or Shorted (DTC 51 (Flash out) / C0225 (Serial communications)).....................................17073
Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash out) / C0221 (Serial communications)).....................................17074
Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash out) / C0235 (Serial communications))...................................17075
Chart B-20 FL Speed Sensor Missing Signal (DTC 61 (Flash out) / C0226, C0227 (Serial communications))...............................17076
Chart B-21 FR Speed Sensor Missing Signal (DTC 62 (Flash out) / C0222, C0223 (Serial communications))...............................17077
Chart B-22 Rear Speed Sensor Missing Signal (DTC 63 (Flash out) / C0236, C0237 (Serial communications)).............................17078
Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal (DTC 64 (Flash out) / C0229 (Serial communications))..................17079
Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash out) / C0238 (Serial communications)).......................................17080
Unit Inspection Procedure...............................................................................................................17081
Chart C-1-1 FL Sensor Output Inspection Procedure...................................................................................17081
Chart C-1-2 FR Sensor Output Inspection Procedure...................................................................................17082
Chart C-1-3 Rear Sensor Output Inspection Procedure.................................................................................17082
Chart TC-1 Sensor Output Inspection Procedure.......................................................................................17083
Special Tools...........................................................................................................................17084
5B ANTI-LOCK BRAKE SYSTEM..................................................................................................................17085
Service Precaution......................................................................................................................17085
Electronic Hydraulic Control Unit.......................................................................................................17086
Electronic Hydraulic Control Unit and Associated Parts..............................................................................17086
Removal.............................................................................................................................17086
Disassembled View...................................................................................................................17087
Disassembly.........................................................................................................................17087
Reassembly..........................................................................................................................17087
Installation........................................................................................................................17087
Front Wheel Speed Sensor................................................................................................................17088
Front Wheel Speed Sensor and Associated Parts.......................................................................................17088
Removal.............................................................................................................................17088
Inspection and Repair...............................................................................................................17088
Installation........................................................................................................................17088
Rear Wheel Speed Sensor.................................................................................................................17089
Removal.............................................................................................................................17089
Inspection and Repair...............................................................................................................17089
Installation........................................................................................................................17089
5C POWER-ASSISTED BRAKE SYSTEM..............................................................................................................17090
Service Precaution......................................................................................................................17091
General Description.....................................................................................................................17091
Diagnosis...............................................................................................................................17095
General Diagnosis.......................................................................................................................17096
Hydraulic Brakes........................................................................................................................17099
Filling Master Cylinder Reservoir...................................................................................................17099
Deterioration of Brake Fluid........................................................................................................17099
Leakage of Brake Fluid..............................................................................................................17099
Bleeding Brake Hydraulic System.....................................................................................................17099
Flushing Brake Hydraulic System.....................................................................................................17100
Brake Pipes and Hoses...............................................................................................................17100
Brake Hose Inspection...............................................................................................................17100
Front Caliper Brake Hose................................................................................................................17101
Front Caliper Brake Hose and Associated Parts.......................................................................................17101
Removal.............................................................................................................................17101
Installation........................................................................................................................17101
Rear Axle Brake Hose....................................................................................................................17102
Rear Axle Brake Hose and Associated Parts...........................................................................................17102
Removal.............................................................................................................................17102
Installation........................................................................................................................17102
Brake Pipe..............................................................................................................................17103
Removal.............................................................................................................................17103
Installation........................................................................................................................17103
P & B (Proportioning and Bypass) Valve..................................................................................................17104
P & B (Proportioning and Bypass) Valve Sectional View...............................................................................17104
Removal.............................................................................................................................17104
Installation........................................................................................................................17104
Main Data and Specifications............................................................................................................17105
Brake Pedal.............................................................................................................................17106
Checking Pedal Height...............................................................................................................17106
Checking Pedal Travel...............................................................................................................17106
Brake Pedal and Associated Parts....................................................................................................17107
Removal.............................................................................................................................17107
Installation........................................................................................................................17107
Stoplight Switch........................................................................................................................17108
Parts Location......................................................................................................................17108
Removal.............................................................................................................................17108
Installation........................................................................................................................17108
Main Data and Specifications............................................................................................................17109
Fluid Reservoir Tank....................................................................................................................17110
Fluid Reservoir Tank and Associated Parts...........................................................................................17110
Removal.............................................................................................................................17110
Installation........................................................................................................................17110
Master Cylinder Assembly................................................................................................................17111
Master Cylinder Assembly and Associated Parts...........................................................................................17111
Removal.............................................................................................................................17111
Inspection and Repair...............................................................................................................17111
Installation........................................................................................................................17112
Main Data and Specifications........................................................................................................17113
Special Tools.......................................................................................................................17113
Vacuum Booster Assembly.................................................................................................................17114
Vacuum Booster Assembly and Associated Parts........................................................................................17114
Removal.............................................................................................................................17114
Inspection and Repair...............................................................................................................17115
Installation........................................................................................................................17115
Exterior Components.....................................................................................................................17117
Exterior Components and Associated Parts............................................................................................17117
Removal.............................................................................................................................17117
Inspection and Repair...............................................................................................................17118
Installation........................................................................................................................17118
Vacuum Booster Overhaul.................................................................................................................17118
Vacuum Booster..........................................................................................................................17118
Main Data and Specifications............................................................................................................17119
Special Tools...........................................................................................................................17120
Front Disc Brake Pads...................................................................................................................17121
Front Disc Brake Pads Inspection....................................................................................................17121
Front Disc Brake Pads and Associated Parts..........................................................................................17121
Removal.............................................................................................................................17122
Installation........................................................................................................................17122
Front Disc Brake Rotor..................................................................................................................17124
Inspection..........................................................................................................................17124
Replacing Brake Rotors..............................................................................................................17124
Refinishing Brake Rotors............................................................................................................17124
Front Disc Brake Caliper Assembly.......................................................................................................17125
Front Disc Brake Caliper Assembly and Associated Parts..............................................................................17125
Removal.............................................................................................................................17126
Installation........................................................................................................................17126
Front Disc Brake Caliper................................................................................................................17128
Front Disc Brake Caliper Disassembled View..........................................................................................17128
Disassembly.........................................................................................................................17128
Inspection and Repair...............................................................................................................17129
Reassembly..........................................................................................................................17129
Main Data and Specifications........................................................................................................17131
Rear Disc Brake Pads (4×4 Model)........................................................................................................17132
Brake Pads Inspection...............................................................................................................17132
Brake Pads and Associated Parts.....................................................................................................17132
Removal.............................................................................................................................17133
Installation........................................................................................................................17133
Rear Disc Brake Rotor (4×4 Model).......................................................................................................17135
Inspection..........................................................................................................................17135
Replacing Brake Rotors..............................................................................................................17135
Refinishing Brake Rotors............................................................................................................17135
Rear Drum (In Disc) Inside Diameter Check...........................................................................................17136
Rear Disc Brake Caliper Assembly (4×4 Model)............................................................................................17137
Rear Disc Brake Caliper Assembly and Associated Parts...............................................................................17137
Removal.............................................................................................................................17137
Installation........................................................................................................................17138
Rear Disc Brake Caliper (4×4 Model).....................................................................................................17139
Rear Disc Brake Caliper Disassembled View...........................................................................................17139
Disassembly.........................................................................................................................17140
Inspection and Repair...............................................................................................................17140
Reassembly..........................................................................................................................17140
Main Data and Specifications (4×4 Model)............................................................................................17142
Brake Lining............................................................................................................................17143
Brake Lining and Associated Parts...................................................................................................17143
Removal.............................................................................................................................17143
Brake Lining Inspection.............................................................................................................17144
Installation........................................................................................................................17144
Drum Brake Adjustment (4×2 Model)...................................................................................................17145
Servicing The Brake Drum............................................................................................................17145
Wheel Cylinder Assembly (4×2 Model).....................................................................................................17146
Wheel Cylinder Assembly and Associated Parts............................................................................................17146
Removal.............................................................................................................................17146
Installation........................................................................................................................17146
Disassembled View...................................................................................................................17147
Disassembly.........................................................................................................................17147
Inspection and Repair...............................................................................................................17147
Reassembly..........................................................................................................................17147
Main Data and Specifications........................................................................................................17149
5D1 PARKING BRAKE SYSTEM (4×4 Model)........................................................................................................17208
Service Precaution......................................................................................................................17208
General Description.....................................................................................................................17208
Operation...............................................................................................................................17209
Parking Brake Lever and Front Cable.....................................................................................................17210
Parking Brake Lever Assembly and Associated Parts...................................................................................17210
Removal.............................................................................................................................17210
Installation........................................................................................................................17210
Parking Brake Rear Cable................................................................................................................17211
Parking Brake Rear Cable and Associated Parts.......................................................................................17211
Removal.............................................................................................................................17212
Installation........................................................................................................................17212
Inspection and Repair...............................................................................................................17213
Parking Brake Lining Inspection.........................................................................................................17213
Main Data and Specifications............................................................................................................17214
5D2 PARKING BRAKE SYSTEM (4×2 Model)........................................................................................................17215
Service Precaution......................................................................................................................17215
General Description.....................................................................................................................17215
Parking Brake Lever.....................................................................................................................17216
Parking Brake Lever Assembly and Associated Parts...................................................................................17216
Removal.............................................................................................................................17216
Installation........................................................................................................................17216
Parking Brake Rear Cable................................................................................................................17217
Parking Brake Rear Cable and Associated Parts.......................................................................................17217
Removal.............................................................................................................................17218
Installation........................................................................................................................17218
Parking Brake Adjustment................................................................................................................17218
Main Data and Specifications............................................................................................................17219
Sec.6 ENGINE..................................................................................................................................17220
6A ENGINE MECHANICAL (6VE1 3.5L)...........................................................................................................17220
Service Precaution......................................................................................................................17221
General Description.....................................................................................................................17222
Engine Diagnosis........................................................................................................................17223
Cylinder Head Cover LH..................................................................................................................17238
Removal.............................................................................................................................17238
Installation........................................................................................................................17239
Cylinder Head Cover RH..................................................................................................................17240
Removal.............................................................................................................................17240
Installation........................................................................................................................17240
Common Chamber..........................................................................................................................17241
Removal.............................................................................................................................17241
Installation........................................................................................................................17241
Exhaust Manifold LH.....................................................................................................................17243
Removal.............................................................................................................................17243
Installation........................................................................................................................17243
Exhaust Manifold RH.....................................................................................................................17244
Removal.............................................................................................................................17244
Installation........................................................................................................................17244
Crankshaft Pulley.......................................................................................................................17245
Removal.............................................................................................................................17245
Installation........................................................................................................................17245
Timing Belt.............................................................................................................................17246
Removal.............................................................................................................................17246
Installation........................................................................................................................17247
Camshaft................................................................................................................................17251
Removal.............................................................................................................................17251
Installation........................................................................................................................17252
Valve Stem Oil Controller , Valve Spring and Valve Guide................................................................................17256
Removal.............................................................................................................................17256
Installation........................................................................................................................17256
Piston, Piston Ring and Connecting Rod..................................................................................................17257
Removal.............................................................................................................................17257
Installation........................................................................................................................17258
Crankshaft and Main Bearings............................................................................................................17259
Removal.............................................................................................................................17259
Installation........................................................................................................................17260
Rear Oil Seal...........................................................................................................................17264
Removal.............................................................................................................................17264
Installation........................................................................................................................17264
Engine Assembly.........................................................................................................................17265
Removal.............................................................................................................................17265
Installation........................................................................................................................17266
Cylinder Head...........................................................................................................................17268
Cylinder Head and Associated Parts..................................................................................................17268
Disassembly.........................................................................................................................17269
Clean...............................................................................................................................17269
Inspection and Repair...............................................................................................................17269
Reassembly..........................................................................................................................17270
Valve Spring, Oil Controller, Valve, Valve Guide........................................................................................17272
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts...............................................................17272
Disassembly.........................................................................................................................17272
Inspection and Repair...............................................................................................................17273
Reassembly..........................................................................................................................17276
Camshaft................................................................................................................................17279
Camshaft and Associated Parts.......................................................................................................17279
Disassembly.........................................................................................................................17279
Inspection and Repair...............................................................................................................17280
Reassembly..........................................................................................................................17282
Crankshaft..............................................................................................................................17286
Crankshaft and Associated Parts.....................................................................................................17286
Disassembly.........................................................................................................................17286
Inspection and Repair for Bearings..................................................................................................17287
Inspection and Repair for Crankshaft................................................................................................17289
Reassembly..........................................................................................................................17290
Piston and Connecting Rod...............................................................................................................17294
Piston, Connecting Rod and Associate Parts..........................................................................................17294
Disassembly.........................................................................................................................17294
Inspection and Repair...............................................................................................................17295
Reassembly..........................................................................................................................17299
Cylinder Block..........................................................................................................................17301
Cylinder Block and Associated Parts.................................................................................................17301
Disassembly.........................................................................................................................17301
Inspection and Repair...............................................................................................................17302
Reassembly..........................................................................................................................17303
Main Data and Specification.............................................................................................................17306
Special Tool............................................................................................................................17312
6B ENGINE COOLING (6VE1 3.5L)...............................................................................................................17314
Service Precaution......................................................................................................................17314
General Description.....................................................................................................................17315
Diagnosis...............................................................................................................................17317
Draining and Refilling Cooling System...................................................................................................17318
Water Pump..............................................................................................................................17319
Water Pump and Associated Parts.....................................................................................................17319
Removal.............................................................................................................................17319
Inspection..........................................................................................................................17319
Installation........................................................................................................................17319
Thermostat..............................................................................................................................17320
Thermostat and Associated Parts.....................................................................................................17320
Removal.............................................................................................................................17320
Inspection..........................................................................................................................17320
Installation........................................................................................................................17320
Radiator................................................................................................................................17321
Radiator and Associated Parts.......................................................................................................17321
Removal.............................................................................................................................17321
Inspection..........................................................................................................................17322
Installation........................................................................................................................17323
Drive Belt and Cooling Fan..............................................................................................................17324
Drive Belt and Associated Parts.....................................................................................................17324
Removal.............................................................................................................................17324
Inspection..........................................................................................................................17324
Installation........................................................................................................................17324
Main Data and Specifications............................................................................................................17325
Special Tool............................................................................................................................17326
6C ENGINE FUEL(6VE1 3.5L)...................................................................................................................17327
General Description.....................................................................................................................17328
General Description.....................................................................................................................17328
Fuel Metering...........................................................................................................................17329
Fuel Filter.............................................................................................................................17330
Removal.............................................................................................................................17330
Inspection..........................................................................................................................17330
Installation........................................................................................................................17331
Inspection..........................................................................................................................17331
In–Tank Fuel Filter.................................................................................................................17331
Fuel Pump Flow Test.................................................................................................................17331
Fuel Pump...............................................................................................................................17332
Fuel Pump and Associated Parts......................................................................................................17332
Removal.............................................................................................................................17332
Installation........................................................................................................................17333
Fuel Tube / Quick ‐ Connector Fittings..................................................................................................17334
Precautions.........................................................................................................................17334
Cautions During Work................................................................................................................17334
Removal.............................................................................................................................17334
Reuse of Quick‐Connector............................................................................................................17335
Assembling Advice...................................................................................................................17335
Fuel Pump Relay.........................................................................................................................17336
General Description.................................................................................................................17336
Fuel Tank...............................................................................................................................17336
Fuel Tank and Associated Parts......................................................................................................17336
Removal.............................................................................................................................17337
Installation........................................................................................................................17337
Fuel Gauge Unit.........................................................................................................................17338
Removal and Installation............................................................................................................17338
Fuel Filler Cap.........................................................................................................................17338
General Description.................................................................................................................17338
Inspection..........................................................................................................................17338
Main Data and Specifications............................................................................................................17339
Special Tool............................................................................................................................17339
6D1 ENGINE ELECTRICAL (6VE1 3.5L)...........................................................................................................17340
Service Precaution......................................................................................................................17340
Battery.................................................................................................................................17341
General Description.....................................................................................................................17341
Diagnosis...............................................................................................................................17341
Battery Charging....................................................................................................................17342
Jump Starting...........................................................................................................................17342
Battery Removal.........................................................................................................................17343
Battery Installation....................................................................................................................17343
Main Data and Specifications............................................................................................................17344
6D2 IGNITION SYSTEM (6VE1 3.5L).............................................................................................................17345
Service Precaution......................................................................................................................17345
General Description.....................................................................................................................17346
Diagnosis...............................................................................................................................17346
Ignition Coil...........................................................................................................................17347
Removal.............................................................................................................................17347
Inspection and Repair...............................................................................................................17347
Installation........................................................................................................................17347
Spark Plug..............................................................................................................................17349
Removal.............................................................................................................................17349
Inspection and Repair...............................................................................................................17349
Installation........................................................................................................................17349
Crankshaft Position Sensor..............................................................................................................17350
Removal.............................................................................................................................17350
Installation........................................................................................................................17350
Main Data and Specifications............................................................................................................17351
6D3 STARTING AND CHARGING SYSTEM............................................................................................................17352
Service Precaution......................................................................................................................17352
Starting System.........................................................................................................................17353
General Description.....................................................................................................................17353
Diagnosis...............................................................................................................................17355
Starter.................................................................................................................................17356
Removal.............................................................................................................................17356
Installation........................................................................................................................17356
Disassembled View...................................................................................................................17358
Disassembly.........................................................................................................................17359
Inspection and Repair...............................................................................................................17361
Reassembly..........................................................................................................................17364
Main Data and Specifications........................................................................................................17365
Charging System.........................................................................................................................17368
General Description.................................................................................................................17368
General On‐Vehicle Inspection.......................................................................................................17368
Generator...............................................................................................................................17369
Removal.............................................................................................................................17369
Inspection..........................................................................................................................17369
Installation........................................................................................................................17370
Disassembled View...................................................................................................................17370
Disassembly.........................................................................................................................17371
Inspection and Repair...............................................................................................................17372
Reassembly..........................................................................................................................17374
Bench Test..........................................................................................................................17375
Main Data and Specifications............................................................................................................17376
6E DRIVEABILITY AND EMISSIONS..............................................................................................................17377
Specifications..........................................................................................................................17382
Tightening Specifications...........................................................................................................17382
Diagrams and Schematics.................................................................................................................17383
PCM Wiring Diagram (1 of 7).........................................................................................................17383
PCM Wiring Diagram (2 of 7).........................................................................................................17384
PCM Wiring Diagram (3 of 7).........................................................................................................17385
PCM Wiring Diagram (4 of 7).........................................................................................................17386
PCM Wiring Diagram (5 of 7).........................................................................................................17387
PCM Wiring Diagram (6 of 7).........................................................................................................17388
PCM Wiring Diagram (7 of 7).........................................................................................................17389
PCM Pinouts.............................................................................................................................17390
PCM Pinout Table, 80-Way Blue Connector-Row “F1～20”.................................................................................17390
PCM Pinout Table, 80-Way Blue Connector-Row “F20～40”................................................................................17391
PCM Pinout Table, 80-Way Blue Connector-Row “F41～60”................................................................................17392
PCM Pinout Table, 80-Way Blue Connector-Row “F61～80”................................................................................17393
PCM Pinout Table, 80-Way Red Connector-Row “S21～40”.................................................................................17397
PCM Pinout Table, 80-Way Red Connector-Row “S41～60”.................................................................................17399
PCM Pinout Table, 80-Way Red Connector-Row “S61～80”.................................................................................17401
Component Locators..................................................................................................................17403
Undercarriage Component Locator.....................................................................................................17405
Fuse and Relay Panel (Underhood Electrical Center)..................................................................................17406
Sensors and Miscellaneous Component Locators........................................................................................17407
Diagnosis...............................................................................................................................17409
Strategy-Based Diagnostics..........................................................................................................17409
DTC Stored..........................................................................................................................17409
No DTC..............................................................................................................................17409
No Matching Symptom.................................................................................................................17409
Intermittents.......................................................................................................................17409
No Trouble Found....................................................................................................................17409
Verifying Vehicle Repair............................................................................................................17409
General Service Information.............................................................................................................17409
OBD II Serviceablity Issues.........................................................................................................17409
Emissions Control Information Label.................................................................................................17410
Visual / Physical Engine Compartment Inspection.....................................................................................17410
Basic Knowledge of Tools Required...................................................................................................17411
Serial Data Communications..............................................................................................................17411
Class 2 Serial Data Communications..................................................................................................17411
On-Board Diagnostic (OBD II)............................................................................................................17411
On-Board Diagnostic Tests...........................................................................................................17411
Comprehensive Component Monitor Diagnostic Operation................................................................................17411
System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...................................17412
Common OBD II Terms.................................................................................................................17412
The Diagnostic Executive............................................................................................................17412
DTC Types...........................................................................................................................17413
Decimal/Binary/Hexadecimal Conversions..............................................................................................17415
Verifying Vehicle Repair............................................................................................................17415
Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool.........................................................................17415
Tech 2..............................................................................................................................17416
Tech 2 Features.....................................................................................................................17417
Getting Started.....................................................................................................................17417
Operating Procedure (For Example)...................................................................................................17418
DTC Modes...........................................................................................................................17419
DTC Information Mode................................................................................................................17419
Miscellaneous Test..................................................................................................................17420
Lamps Test..........................................................................................................................17420
Relays Test.........................................................................................................................17422
EVAP Test...........................................................................................................................17423
Fuel System Test....................................................................................................................17424
Instruments Test....................................................................................................................17426
EGR Control Test....................................................................................................................17428
Variable Intake Manifold Solenoid Test..............................................................................................17428
Injector Balance Test...............................................................................................................17430
Plotting Snapshot Graph.................................................................................................................17430
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)......................................................17431
Flow Chart for Snapshot Replay (Plotting Graph).....................................................................................17432
Primary System-Based Diagnostic.........................................................................................................17433
Primary System-Based Diagnostic.....................................................................................................17433
Fuel Control Heated Oxygen Sensor...................................................................................................17433
HO2S Heater.........................................................................................................................17433
Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation.....................................................................17433
Misfire Monitor Diagnostic Operation....................................................................................................17434
Misfire Monitor Diagnostic Operation................................................................................................17434
Misfire Counters....................................................................................................................17434
Fuel Trim System Monitor Diagnostic Operation...........................................................................................17435
Fuel Trim System Monitor Diagnostic Operation.......................................................................................17435
Fuel Trim Cell Diagnostic Weights...................................................................................................17435
On-Board Diagnostic (OBD II) System Check...............................................................................................17436
Circuit Description.................................................................................................................17436
Diagnostic Aids.....................................................................................................................17436
Test Description....................................................................................................................17436
A/C Clutch Control Circuit Diagnosis....................................................................................................17439
Circuit Description.................................................................................................................17439
Diagnostic Aids.....................................................................................................................17439
A/C Clutch Diagnosis................................................................................................................17440
Electronic Ignition System Diagnosis....................................................................................................17444
EVAP Canister Purge Solenoid and EVAP Vent Solenoid Valve...............................................................................17444
Visual Check of The Evaporative Emission Canister.......................................................................................17444
Fuel Metering System Check..............................................................................................................17444
Fuel System Pressure Test...............................................................................................................17444
Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure..............................................................17444
Test Description....................................................................................................................17444
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)...........................................17445
Powertrain Control Module (PCM) Diagnosis...............................................................................................17449
Multiple PCM Information Sensor DTCs Set................................................................................................17449
Circuit Description.................................................................................................................17449
Diagnostic Aids.....................................................................................................................17449
Exhaust Gas Recirculation (EGR) Diagnosis...............................................................................................17452
Engine Tech 2 Data Definitions and Ranges...............................................................................................17452
Typical Scan Data Values................................................................................................................17454
Test Conditions.....................................................................................................................17454
No Malfunction Indicator Lamp (MIL).....................................................................................................17460
Circuit Description.................................................................................................................17460
Diagnostic Aids.....................................................................................................................17460
Malfunction Indicator Lamp (MIL) “ON” Steady............................................................................................17463
Circuit description.................................................................................................................17463
Diagnostic Aids.....................................................................................................................17463
No Reduced Power Lamp (RPL).............................................................................................................17465
Circuit Description.................................................................................................................17465
Diagnostic Aids.....................................................................................................................17465
Test Description....................................................................................................................17465
Reduced Power Lamp (RPL) “ON” Steady....................................................................................................17469
Circuit Description.................................................................................................................17469
Diagnostic Aids.....................................................................................................................17469
Test Description....................................................................................................................17469
Starter Control System Check............................................................................................................17472
Circuit Description.................................................................................................................17472
Diagnostic Aids.....................................................................................................................17472
Engine Cranks But Will Not Run..........................................................................................................17476
Circuit Description.................................................................................................................17478
Diagnostic Aids.....................................................................................................................17478
Test Description....................................................................................................................17478
Fuel System Electrical Test.............................................................................................................17483
Circuit Description.................................................................................................................17484
Diagnostic Aids.....................................................................................................................17484
Test Description....................................................................................................................17484
Fuel Pressure Relief Procedure......................................................................................................17484
Electric Throttle Control (ETC) System Check............................................................................................17487
Circuit Description.................................................................................................................17488
Diagnostic Aids.....................................................................................................................17488
Test Description....................................................................................................................17488
Fuel System Diagnosis...................................................................................................................17491
Circuit Description.................................................................................................................17492
Test Description....................................................................................................................17492
Fuel Pressure Relief Procedure......................................................................................................17493
Exhaust Gas Recirculation (EGR) System Check............................................................................................17496
Circuit Description.................................................................................................................17496
Manifold Absolute Pressure (MAP) Output Check...........................................................................................17498
Circuit Description.................................................................................................................17498
Evaporative (EVAP) Emissions Canister Purge Valve Check.................................................................................17500
Circuit Description.................................................................................................................17500
Diagnostic Aids.....................................................................................................................17500
PCM Diagnostic Trouble Codes............................................................................................................17503
Diagnostic Trouble Code (DTC) P0101 MAF System Performance..............................................................................17507
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency....................................................................17510
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency...................................................................17513
Diagnostic Trouble Code (DTC) P0106 MAP System Performance..............................................................................17516
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage......................................................................17519
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage.....................................................................17522
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage......................................................................17525
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage.....................................................................17528
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage......................................................................17531
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage.....................................................................17534
Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control......................................................17537
Diagnostic Trouble Code(DTC) P0128 Thermostat Insufficient Temperature for Stable Operation.............................................17540
Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1............................................................17542
Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1...........................................................17545
Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1..................................................................17548
Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1..................................................17552
Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1.................................................................17555
Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2............................................................17558
Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2...........................................................17561
Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2...................................................17564
Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2.................................................................17567
Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1............................................................17570
Diagnostic Trouble Code (DTC) P0152 HO2S Circuit High Voltage Bank 2 Sensor 1...........................................................17573
Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1..................................................................17576
Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1..................................................17580
Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Open Bank 2 Sensor 1............................................................17583
Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2............................................................17586
Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2...........................................................17589
Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2..................................................17592
Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2.................................................................17595
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1........................................................................17598
Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1........................................................................17602
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2........................................................................17606
Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2........................................................................17610
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit..........................................................................17614
Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit..........................................................................17617
Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit..........................................................................17620
Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit..........................................................................17623
Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit..........................................................................17626
Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit..........................................................................17629
Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected.............................................................................17632
Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected...........................................................................17636
Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected...........................................................................17638
Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected...........................................................................17640
Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected...........................................................................17642
Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected...........................................................................17644
Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected...........................................................................17646
Diagnostic Trouble Code (DTC) P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault........................................17648
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit........................................................................17651
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency....................................................................17654
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit..........................................................................17657
Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit..........................................................................17660
Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit..........................................................................17663
Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit..........................................................................17666
Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit..........................................................................17669
Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit..........................................................................17672
Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient...............................................................................17675
Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error..............................................................................17678
Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck......................................................................................17680
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage....................................................................................17685
Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1....................................................................17688
Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2....................................................................17691
Diagnostic Trouble Code (DTC) P0440 EVAP System.........................................................................................17694
Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected.....................................................................17697
Diagnostic Trouble Code (DTC) P0444 EVAP Purge Control Circuit Open.....................................................................17700
Diagnostic Trouble Code (DTC) P0445 EVAP Purge Control Circuit Short....................................................................17702
Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Control Malfunction..............................................................17704
Diagnostic Trouble Code (DTC) P0447 EVAP Vent Solenoid Circuit Open.....................................................................17707
Diagnostic Trouble Code (DTC) P0448 EVAP Vent solenoid Circuit Short....................................................................17709
Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) Low Voltage.......................................17711
Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) High Voltage......................................17714
Diagnostic Trouble Code (DTC) P0456 EVAP Very Small Leak................................................................................17717
Diagnostic Trouble Code (DTC) P0461 Fuel Level Sensor Performance.......................................................................17720
Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit‐Low Voltage...............................................................17722
Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit‐High Voltage..............................................................17725
Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Noisy Signal......................................................................17727
Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input...............................................................................17729
Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM.....................................................................17732
Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM....................................................................17735
Diagnostic Trouble Code (DTC) P0562 System Voltage Low..................................................................................17738
Diagnostic Trouble Code (DTC) P0563 System Voltage High.................................................................................17740
Diagnostic Trouble Code (DTC) P0565 Cruise Main Switch Circuit Error....................................................................17742
Diagnostic Trouble Code (DTC) P0566 Cruise Cancel Switch Circuit Error..................................................................17744
Diagnostic Trouble Code (DTC) P0567 Cruise Resume Switch Circuit Error..................................................................17746
Diagnostic Trouble Code (DTC) P0568 Cruise Set Switch Circuit Error.....................................................................17748
Diagnostic Trouble Code (DTC) P0571 No Brake Switch Signal..............................................................................17750
Diagnostic Trouble Code (DTC) P0601 PCM Memory..........................................................................................17752
Diagnostic Trouble Code (DTC) P0602 PCM Programming Error...............................................................................17754
Diagnostic Trouble Code (DTC) P0604 PCM RAM Error.......................................................................................17756
Diagnostic Trouble Code (DTC) P0606 PCM Internal Performance............................................................................17758
Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage........................................................17760
Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage................................................................17762
Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage........................................................17764
Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage.........................................................17767
Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage.........................................................17769
Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage........................................................17771
Diagnostic Trouble Code(DTC) P1120-TPS 1 Throttle Position Sensor (TPS1) Output Abnormal................................................17774
Diagnostic Trouble Code (DTC) P1125 ETC (Electric Throttle Control) Limit Performance Mode..............................................17777
Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1.........................................................17780
Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1..........................................................17784
Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1.........................................................17788
Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1..................................................17792
Diagnostic Trouble Code (DTC) P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1).................................................17796
Diagnostic Trouble Code (DTC) P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2).................................................17798
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration................................................................17800
Diagnostic Trouble Code (DTC) P1220 Throttle Position Senser2 (TPS2) Circuit Fault......................................................17803
Diagnosis Trouble Code(DTC) P1221 TPS1- TPS2 Correlation(Circuit Performance)...........................................................17806
Diagnostic Trouble Code (DTC) P1271 APS 1-2 Correlation Error...........................................................................17809
Diagnostic Trouble Code (DTC) P1272 APS 2-3 Correlation Error...........................................................................17812
Diagnostic Trouble Code (DTC) P1273 APS 1-3 Correlation Error...........................................................................17815
Diagnostic Trouble Code (DTC) P1275 APS 1 Output Fault..................................................................................17818
Diagnostic Trouble Code (DTC) P1280 APS 2 Output Fault..................................................................................17820
Diagnostic Trouble Code (DTC) P1285 APS 3 Output Fault..................................................................................17822
Diagnostic Trouble Code (DTC) P1290 ETC Forced Idle Mode................................................................................17824
Diagnostic Trouble Code (DTC) P1295 ETC Power Management Mode...........................................................................17827
Diagnostic Trouble Code (DTC) P1299 ETC Forced Engine Shutdown Mode.....................................................................17831
Diagnostic Trouble Code (DTC) P1310 ION Sensing Module Diagnosis........................................................................17835
Diagnostic Trouble Code (DTC) P1311 ION Sensing Module SEC Line 1 Circuit Fault.........................................................17838
Diagnostic Trouble Code (DTC) P1312 ION Sensing Module SEC Line 2 Circuit Fault.........................................................17841
Diagnostic Trouble Code (DTC) P1326 ION Sensing Module Combustion Quality Input Circuit Fault...........................................17844
Diagnostic Trouble Code (DTC) P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)................................17847
Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed....................................................................................17850
Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge...................................................................17853
Diagnostic Trouble Code (DTC) P1514 TPS - MAF Correlation Error.........................................................................17856
Diagnostic Trouble Code (DTC) P1515 Command - Actual TPS Correlation Error..............................................................17860
Diagnostic Trouble Code (DTC) P1516 Command - Actual TPS Correlation Error..............................................................17863
Diagnostic Trouble Code (DTC) P1523 Actuator Control Return Performance.................................................................17866
Diagnostic Trouble Code (DTC) P1571 Brake Switch No Operation...........................................................................17869
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset................................................................................17871
Diagnostic Trouble Code (DTC) P1635 Reference Voltage # 1 Circuit Fault.................................................................17872
Diagnostic Trouble Code (DTC) P1639 Reference Voltage # 2 Circuit Fault.................................................................17874
Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM).................................................................17876
Diagnostic Trouble Code (DTC) P1650 Quad Driver Module “A” Fault........................................................................17879
Symptom Diagnosis.......................................................................................................................17882
Default Matrix Table....................................................................................................................17911
On Vehicle Service Crankshaft Position (CKP) Sensor.....................................................................................17914
Engine Coolant Temperature (ECT) Sensor.................................................................................................17914
Heated Oxygen Sensor (HO2S).............................................................................................................17915
Intake Air Temperature (IAT) Sensor.....................................................................................................17918
ION Sensing Module......................................................................................................................17918
Mass Air Flow (MAF) Sensor..............................................................................................................17919
Manifold Absolute Pressure (MAP) Sensor.................................................................................................17920
Malfunction Indicator Lamp (MIL)........................................................................................................17921
Reduced Power Lamp......................................................................................................................17921
Powertrain Control Module(PCM)..........................................................................................................17921
Service Precaution......................................................................................................................17921
EEPROM..................................................................................................................................17923
Throttle Position (TP) Sensor...........................................................................................................17923
Vehicle Speed Sensor (VSS)..............................................................................................................17924
Air Cleaner/Air Filter..................................................................................................................17925
Common Chamber..........................................................................................................................17925
Accelerator Pedal Replacement...........................................................................................................17926
Accelerator Position Sensor Replacement.................................................................................................17927
Accelerator Position Sensor Adjustment..................................................................................................17927
Fuel Filler Cap.........................................................................................................................17928
Fuel Filter.............................................................................................................................17928
Fuel Gauge Unit.........................................................................................................................17929
Fuel Injectors..........................................................................................................................17930
Fuel Metering System....................................................................................................................17931
Fuel Pump Assembly......................................................................................................................17931
Fuel Pump Relay.........................................................................................................................17932
Fuel Rail Assembly......................................................................................................................17933
Fuel Tank...............................................................................................................................17934
Throttle Body (TB)......................................................................................................................17934
Electronic Ignition System..............................................................................................................17936
Catalytic Converter.....................................................................................................................17937
Air Conditioning Thermo Relay...........................................................................................................17937
EVAP Canister Hoses.....................................................................................................................17937
EVAP Canister...........................................................................................................................17938
EVAP Canister Vent Solenoid.............................................................................................................17938
Fuel Tank Pressure (Vapor Pressure) Sensor..............................................................................................17939
Fuel Tank Vent Valve (Vent Solenoid Valve)..............................................................................................17941
Linear Exhaust Gas Recirculation (EGR) Valve............................................................................................17941
Positive Crankcase Ventilation (PCV) Valve..............................................................................................17942
Wiring and Connectors...................................................................................................................17942
PCM Connectors and Terminals............................................................................................................17943
Wire Harness Repair: Twisted Shielded Cable.............................................................................................17943
Twisted Leads...........................................................................................................................17944
Weather-Pack Connector..................................................................................................................17945
Com-Pack III............................................................................................................................17946
Metri-Pack..............................................................................................................................17947
General Description (PCM and Sensors)...................................................................................................17948
General Description (Air Induction).....................................................................................................17953
General Description (Fuel Metering).....................................................................................................17954
General Description (Electronic Ignition System)........................................................................................17956
A/C Clutch Diagnosis....................................................................................................................17959
General Description (Evaporative (EVAP) Emission System)................................................................................17959
General Description (Exhaust Gas Recirculation (EGR) System)............................................................................17964
General Description (Positive Crankcase Ventilation (PCV) System).......................................................................17965
Special Tools...........................................................................................................................17967
6F ENGINE EXHAUST (6VE1 3.5L)..............................................................................................................17969
Service Precaution......................................................................................................................17969
General Description.....................................................................................................................17970
Three Way Catalytic Converter RH and Forked Exhaust Pipe................................................................................17971
Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts.......................................................17971
Removal.............................................................................................................................17971
Installation........................................................................................................................17971
Three Way Catalytic Converter LH and Forked Exhaust Pipe................................................................................17972
Removal.............................................................................................................................17972
Installation........................................................................................................................17972
Forked Exhaust Pipe.....................................................................................................................17973
Forked Exhaust Pipe and Associated Parts............................................................................................17973
Removal.............................................................................................................................17973
Installation........................................................................................................................17973
Exhaust Silencer........................................................................................................................17974
Exhaust Silencer and Associated Parts...............................................................................................17974
Removal.............................................................................................................................17974
Installation........................................................................................................................17974
Rear Exhaust pipe.......................................................................................................................17975
Rear Exhaust pipe and Associated Parts..............................................................................................17975
Removal.............................................................................................................................17975
Installation........................................................................................................................17975
Main Data and Specifications............................................................................................................17976
6G ENGINE LUBRICATION (6VE1 3.5L)..........................................................................................................17977
Service Precaution......................................................................................................................17977
General Description.....................................................................................................................17978
Oil Pump................................................................................................................................17979
Oil Pump and Associated Parts.......................................................................................................17979
Disassembly.........................................................................................................................17980
Inspection and Repair...............................................................................................................17980
Reassembly..........................................................................................................................17981
Oil Pan and Crankcase...................................................................................................................17983
Removal.............................................................................................................................17983
Installation........................................................................................................................17983
Oil Pump................................................................................................................................17985
Removal.............................................................................................................................17985
Installation........................................................................................................................17985
Oil Pump Oil Seal.......................................................................................................................17987
Removal.............................................................................................................................17987
Installation........................................................................................................................17987
Oil Filter..............................................................................................................................17988
Removal.............................................................................................................................17988
Installation........................................................................................................................17988
Main Data and Specification.............................................................................................................17989
6H ENGINE SPEED CONTROL SYSTEM.............................................................................................................17990
Service Precaution......................................................................................................................17990
Accelerator Pedal.......................................................................................................................17991
Accelerator Pedal and Associated Parts..............................................................................................17991
Removal.............................................................................................................................17991
Installation........................................................................................................................17991
6J INDUCTION (6VE1 3.5L)...................................................................................................................17992
Service Precaution......................................................................................................................17992
Air Cleaner Element.....................................................................................................................17993
Removal.............................................................................................................................17993
Inspection..........................................................................................................................17993
Installation........................................................................................................................17993
Sec.7 TRANSMISSION............................................................................................................................17994
7A AUTOMATIC TRANSMISSION (4L30‐E).........................................................................................................17994
Service Precaution......................................................................................................................17995
Construction............................................................................................................................17996
Range Reference Chart...................................................................................................................17997
Normal Operation Of 2002 4L30‐E Transmission............................................................................................17998
Diagnosis...............................................................................................................................17998
Driver Information......................................................................................................................17998
General Diagnosis Procedure.............................................................................................................18001
Preliminary Inspection Chart............................................................................................................18002
Checking Transmission Fluid Level and Condition.........................................................................................18003
Test Driving............................................................................................................................18004
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................18005
Mechanical / Hydraulic Diagnosis Symptoms Index.........................................................................................18006
Stall Test..............................................................................................................................18016
Line Pressure Test......................................................................................................................18016
Shift Speed Chart.......................................................................................................................18017
Lockup Speed Chart......................................................................................................................18019
Changing Transmission Fluid.............................................................................................................18020
Selector Lever..........................................................................................................................18020
Inspection..........................................................................................................................18020
Removal.............................................................................................................................18020
Installation........................................................................................................................18022
Select Cable............................................................................................................................18022
Removal.............................................................................................................................18022
Installation........................................................................................................................18025
Shift Lock Cable........................................................................................................................18027
Removal.............................................................................................................................18027
Installation........................................................................................................................18027
Mode Switch.............................................................................................................................18028
Removal.............................................................................................................................18028
Installation........................................................................................................................18029
Transmission Assembly...................................................................................................................18030
Transmission and Associated Parts...................................................................................................18030
Removal.............................................................................................................................18031
Installation........................................................................................................................18036
Solenoid (Main Case Valve Body).........................................................................................................18040
Removal.............................................................................................................................18040
Installation........................................................................................................................18040
Solenoid (Adapter Case Valve Body)......................................................................................................18041
Removal.............................................................................................................................18041
Installation........................................................................................................................18041
Valve Body Assembly (Main Case).........................................................................................................18042
Removal.............................................................................................................................18042
Installation........................................................................................................................18042
Valve Body Assembly (Adapter Case)......................................................................................................18043
Removal.............................................................................................................................18043
Installation........................................................................................................................18043
Powertrain Control Module (PCM).........................................................................................................18043
Removal.............................................................................................................................18043
Installation........................................................................................................................18043
Speed Sensor (Extension Assembly).......................................................................................................18044
Removal.............................................................................................................................18044
Installation........................................................................................................................18044
Transmission Oil Temperature Sensor (Main Case).........................................................................................18045
Removal.............................................................................................................................18045
Installation........................................................................................................................18045
Front Oil Seal (Converter Housing)......................................................................................................18046
Removal.............................................................................................................................18046
Installation........................................................................................................................18046
Rear Oil Seal (Extension Assembly)......................................................................................................18046
Removal.............................................................................................................................18046
Installation........................................................................................................................18046
Transmission (4L30‐E)...................................................................................................................18047
Disassembly.........................................................................................................................18047
Reassembly..........................................................................................................................18051
Converter Housing And Oil Pump Assembly.................................................................................................18061
Disassembled View...................................................................................................................18061
Disassembly.........................................................................................................................18061
Inspection And Repair...............................................................................................................18061
Reassembly..........................................................................................................................18061
Oil Pump................................................................................................................................18062
Disassembled View...................................................................................................................18062
Disassembly.........................................................................................................................18062
Inspection And Repair...............................................................................................................18063
Reassembly..........................................................................................................................18063
Main Case Valve Body....................................................................................................................18064
Disassembled View...................................................................................................................18064
Disassembly.........................................................................................................................18064
Inspection And Repair...............................................................................................................18065
Reassembly..........................................................................................................................18065
Adapter Case Valve Body.................................................................................................................18066
Disassembled View...................................................................................................................18066
Disassembly.........................................................................................................................18066
Inspection And Repair...............................................................................................................18066
Reassembly..........................................................................................................................18067
Third Clutch And Sprag Unit.............................................................................................................18068
Disassembled View...................................................................................................................18068
Disassembly.........................................................................................................................18068
Inspection And Repair...............................................................................................................18068
Reassembly..........................................................................................................................18069
Third Clutch............................................................................................................................18070
Disassembled View...................................................................................................................18070
Disassemble.........................................................................................................................18070
Inspection And Repair...............................................................................................................18070
Reassembly..........................................................................................................................18070
Sprag Unit..............................................................................................................................18072
Disassembled View...................................................................................................................18072
Disassembly.........................................................................................................................18072
Inspection And Repair...............................................................................................................18072
Reassembly..........................................................................................................................18072
Second Clutch...........................................................................................................................18073
Disassembled View...................................................................................................................18073
Disassembly.........................................................................................................................18073
Inspection And Repair...............................................................................................................18074
Reassembly..........................................................................................................................18074
3‐4 Accumulator Piston..................................................................................................................18075
Disassembled View...................................................................................................................18075
Disassembly.........................................................................................................................18075
Inspection And Repair...............................................................................................................18076
Reassembly..........................................................................................................................18076
Reverse Clutch Piston And Center Support................................................................................................18077
Disassembled View...................................................................................................................18077
Disassembly.........................................................................................................................18077
Inspection And Repair...............................................................................................................18078
Reassembly..........................................................................................................................18078
Overrun Clutch And Turbine Shaft........................................................................................................18079
Disassembled View...................................................................................................................18079
Disassembly.........................................................................................................................18080
Inspection And Repair...............................................................................................................18080
Reassembly..........................................................................................................................18080
Main Data And Specification.............................................................................................................18082
General Specifications..............................................................................................................18082
Torque Specifications...............................................................................................................18083
Special Tools...........................................................................................................................18086
4L30-E Parts List.......................................................................................................................18089
7A1 TRANSMISSION CONTROL SYSTEM (4L30‐E)....................................................................................................18097
Service Precaution......................................................................................................................18098
General Description.....................................................................................................................18098
Electronic Control Diagram..........................................................................................................18099
Powertrain Control Module (PCM).....................................................................................................18100
Control System Diagram..............................................................................................................18101
Shift Control.......................................................................................................................18102
Band Apply Control..................................................................................................................18102
Torque Converter Clutch Control (Electronically Controlled Capacity Clutch = ECCC)..................................................18102
Line Pressure Control...............................................................................................................18102
On‐Board Diagnostic System..........................................................................................................18102
Fail Safe Mechanism.................................................................................................................18102
Torque Management Control...........................................................................................................18102
ATF Warning Control.................................................................................................................18102
Reverse Lock Out Control............................................................................................................18102
Downhill Control....................................................................................................................18102
Uphill Control......................................................................................................................18102
Shift Mode Control..................................................................................................................18103
Gear Shift Control..................................................................................................................18104
Winter Drive Mode...................................................................................................................18105
Backup Mode.........................................................................................................................18105
Functions of Input / Output Components..............................................................................................18106
Diagnosis...............................................................................................................................18107
Electronic Diagnosis................................................................................................................18107
Check Trans Indicator...............................................................................................................18107
Diagnostic Check....................................................................................................................18107
“Check Trans” Check.................................................................................................................18108
Tech 2 OBD II Connection............................................................................................................18109
Transmission Data...................................................................................................................18114
OBD II Diagnostic Management System.................................................................................................18115
16-Terminal Data Link Connector (DLC)...............................................................................................18116
Malfunction Indicator Lamp (MIL)....................................................................................................18117
DTC Types...........................................................................................................................18117
Clear DTC...........................................................................................................................18118
DTC Check...........................................................................................................................18118
PCM Precaution......................................................................................................................18118
Information On PCM..................................................................................................................18118
Intermittent Conditions.............................................................................................................18119
Transmission And PCM Identification.................................................................................................18119
Diagnostic Trouble Code (DTC) Identification........................................................................................18120
DTC P0218 Transmission Fluid Over Temperature...........................................................................................18121
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position......................................................................18123
DTC P0706 Transmission Range Switch (Mode Switch) Performance...........................................................................18126
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance.......................................................................18129
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input.................................................................18132
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................18135
DTC P0719 Brake Switch Circuit Low (Stuck On)...........................................................................................18138
DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input....................................................................18141
DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent.................................................................18144
DTC P0724 Brake Switch Circuit High (Stuck Off).........................................................................................18147
DTC P0730 Gear Error Without Input Speed................................................................................................18149
DTC P0742 Torque Converter Clutch (TCC) System Stuck On.................................................................................18152
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical..............................................................18154
DTC P0751 Shift Solenoid A Performance (Stuck Off)......................................................................................18156
DTC P0752 Shift Solenoid A Performance (Stuck On).......................................................................................18158
DTC P0753 Shift Solenoid A Electrical...................................................................................................18160
DTC P0756 Shift Solenoid B Performance (Stuck Off)......................................................................................18163
DTC P0757 Shift Solenoid B Performance (Stuck On).......................................................................................18165
DTC P0758 Shift Solenoid B Electrical...................................................................................................18167
DTC P1850 Brake Band Apply Solenoid Malfunction.........................................................................................18171
DTC P1860 TCC PWM Solenoid Electrical...................................................................................................18175
DTC P1870 Transmission Component Slipping (TCC Stuck Off)...............................................................................18178
Circuit Diagram.........................................................................................................................18180
Parts Location..........................................................................................................................18182
Harness Connector Faces.................................................................................................................18183
Transmission Fluid Temperature (TFT) Sensor Specifications..............................................................................18185
Sec.8 BODY AND ACCESSORIES....................................................................................................................18186
8A LIGHTING SYSTEM..........................................................................................................................18186
Service Precaution......................................................................................................................18187
Headlight Bulb..........................................................................................................................18188
Removal.............................................................................................................................18188
Installation........................................................................................................................18188
Headlight Assembly......................................................................................................................18189
Removal.............................................................................................................................18189
Installation........................................................................................................................18189
Headlight Adjustment................................................................................................................18189
Side Marker Light Bulb..................................................................................................................18191
Removal.............................................................................................................................18191
Installation........................................................................................................................18191
Taillight Bulb..........................................................................................................................18192
Removal.............................................................................................................................18192
Installation........................................................................................................................18192
License Plate Light Bulb................................................................................................................18193
Removal.............................................................................................................................18193
Installation........................................................................................................................18193
Stoplight Bulb..........................................................................................................................18193
Removal and Installation............................................................................................................18193
High Mounted Stoplight Assembly.........................................................................................................18194
Removal.............................................................................................................................18194
Installation........................................................................................................................18194
High Mounted Stoplight Bulb.............................................................................................................18194
Removal.............................................................................................................................18194
Installation........................................................................................................................18194
Backup Light Bulb.......................................................................................................................18195
Removal.............................................................................................................................18195
Installation........................................................................................................................18195
Front Turn Signal Light Bulb............................................................................................................18195
Removal and Installation............................................................................................................18195
Rear Turn Signal Light Bulb.............................................................................................................18196
Removal.............................................................................................................................18196
Installation........................................................................................................................18196
Dome Light Bulb.........................................................................................................................18196
Removal.............................................................................................................................18196
Installation........................................................................................................................18196
Map Light Bulb..........................................................................................................................18197
Removal.............................................................................................................................18197
Installation........................................................................................................................18197
Courtesy Light Bulb.....................................................................................................................18197
Removal.............................................................................................................................18197
Installation........................................................................................................................18197
Luggage Room Light Bulb.................................................................................................................18198
Removal.............................................................................................................................18198
Installation........................................................................................................................18198
Shift Lever Illumination Light Bulb (A/T)...............................................................................................18198
Removal.............................................................................................................................18198
Installation........................................................................................................................18198
Vanity Mirror Illumination Light Bulb...................................................................................................18199
Removal.............................................................................................................................18199
Installation........................................................................................................................18199
Switch Unit Assembly Illumination Light Bulb (Power/Winter & Intelligent Suspension Switch).............................................18199
Removal.............................................................................................................................18199
Installation........................................................................................................................18199
TOD Switch Illumination Light Bulb......................................................................................................18200
Removal.............................................................................................................................18200
Installation........................................................................................................................18200
Cruise Control Main Switch Illumination Light Bulb......................................................................................18200
Removal.............................................................................................................................18200
Installation........................................................................................................................18200
Rear Wiper and Washer Switch Illumination Light Bulb....................................................................................18201
Removal.............................................................................................................................18201
Installation........................................................................................................................18201
Seat Heater Switch Illumination Light Bulb..............................................................................................18201
Removal.............................................................................................................................18201
Installation........................................................................................................................18201
Starter Switch..........................................................................................................................18202
Removal and Installation............................................................................................................18202
Lighting Switch (Combination Switch)....................................................................................................18202
Removal and Installation............................................................................................................18202
Dimmer Passing Switch (Combination Switch)..............................................................................................18202
Removal and Installation............................................................................................................18202
Front Door Switch.......................................................................................................................18202
Removal.............................................................................................................................18202
Installation........................................................................................................................18202
Rear Door Switch........................................................................................................................18203
Removal.............................................................................................................................18203
Installation........................................................................................................................18203
Tailgate Lock Switch....................................................................................................................18203
Removal.............................................................................................................................18203
Installation........................................................................................................................18203
Key Remind Switch (Starter Switch)......................................................................................................18204
Removal and Installation............................................................................................................18204
Hazard Warning Light Switch.............................................................................................................18204
Removal.............................................................................................................................18204
Installation........................................................................................................................18204
Stoplight Switch........................................................................................................................18205
Removal and Installation............................................................................................................18205
Turn Signal Light Switch (Combination Switch)...........................................................................................18205
Removal and Installation............................................................................................................18205
Illumination Controller.................................................................................................................18205
Removal.............................................................................................................................18205
Installation........................................................................................................................18205
Main Data and Specifications............................................................................................................18206
8B WIPER / WASHER SYSTEM....................................................................................................................18208
Service Precaution......................................................................................................................18208
Windshield Wiper/Washer System..........................................................................................................18209
General Description.....................................................................................................................18209
Windshield Wiper And Washer Switch......................................................................................................18209
Removal and Installation............................................................................................................18209
Windshield Wiper Motor..................................................................................................................18209
Removal.............................................................................................................................18209
Installation........................................................................................................................18209
Windshield Washer Motor.................................................................................................................18210
Removal.............................................................................................................................18210
Installation........................................................................................................................18210
Windshield Washer Spray Pattern.........................................................................................................18211
Windshield Wiper Linkage................................................................................................................18212
Windshield Wiper Linkage and Associated Parts.......................................................................................18212
Removal.............................................................................................................................18212
Installation........................................................................................................................18212
Windshield Wiper Arm/Blade..............................................................................................................18213
Removal.............................................................................................................................18213
Installation........................................................................................................................18213
Windshield Wiper Blade Rubber...........................................................................................................18214
Removal.............................................................................................................................18214
Installation........................................................................................................................18214
Rear Wiper/Washer System................................................................................................................18215
General Description.................................................................................................................18215
Rear Wiper and Washer Switch............................................................................................................18215
Removal.............................................................................................................................18215
Installation........................................................................................................................18215
Rear Wiper Motor........................................................................................................................18216
Removal.............................................................................................................................18216
Installation........................................................................................................................18216
Rear Washer Motor.......................................................................................................................18217
Removal.............................................................................................................................18217
Installation........................................................................................................................18217
Alarm and Relay Control Unit............................................................................................................18218
Removal.............................................................................................................................18218
Installation........................................................................................................................18218
Rear Wiper Arm/Blade....................................................................................................................18218
Removal.............................................................................................................................18218
Installation........................................................................................................................18218
Rear Washer Nozzle......................................................................................................................18219
Removal.............................................................................................................................18219
Installation........................................................................................................................18219
Rear Washer Spray Pattern...........................................................................................................18219
Rear Wiper Blade Rubber.................................................................................................................18220
Removal.............................................................................................................................18220
Installation........................................................................................................................18220
Main Data and Specifications............................................................................................................18221
8C ENTERTAINMENT............................................................................................................................18222
Service Precaution......................................................................................................................18222
Cigarette Lighter.......................................................................................................................18223
General Description.....................................................................................................................18223
Removal.............................................................................................................................18223
Installation........................................................................................................................18223
Rod Type Antenna........................................................................................................................18224
Removal.............................................................................................................................18224
Installation........................................................................................................................18224
Accessory Socket........................................................................................................................18225
Front Accessory Socket..............................................................................................................18225
Removal.............................................................................................................................18225
Installation........................................................................................................................18225
Rear Accessory Socket...............................................................................................................18225
Removal.............................................................................................................................18225
Installation........................................................................................................................18225
Speaker.................................................................................................................................18227
Front Speaker.......................................................................................................................18227
Removal.............................................................................................................................18227
Installation........................................................................................................................18227
Front Tweeter Assembly..............................................................................................................18227
Removal.............................................................................................................................18227
Installation........................................................................................................................18227
Rear Door Speaker...................................................................................................................18227
Removal.............................................................................................................................18227
Installation........................................................................................................................18228
Rear Tweeter Assembly...............................................................................................................18228
Removal.............................................................................................................................18228
Installation........................................................................................................................18228
Horn....................................................................................................................................18229
Removal.............................................................................................................................18229
Installation........................................................................................................................18229
Display (MID)...........................................................................................................................18229
Removal.............................................................................................................................18229
Installation........................................................................................................................18229
MID Control Unit........................................................................................................................18230
Removal.............................................................................................................................18230
Installation........................................................................................................................18230
GPS Control Unit........................................................................................................................18231
Removal.............................................................................................................................18231
Installation........................................................................................................................18231
Self-Diagnosis..........................................................................................................................18232
Self-Diagnosis Flow Char-1..........................................................................................................18232
Self-Diagnosis Flow Char-2 (Audio)..................................................................................................18233
Self-Diagnosis Flow Char-3 (Display)................................................................................................18234
Self-Diagnosis Flow Char-4 (MID)....................................................................................................18235
Audio Self-Diagnosis................................................................................................................18236
Display Self-Diagnosis..............................................................................................................18237
MID Self-Diagnosis..................................................................................................................18238
Symptom Diagnosis.......................................................................................................................18239
MID Not Appears.....................................................................................................................18239
No COMPASS, CLOCK, FUEL CONSUMPTION, or SERVICE Display.............................................................................18240
No COMPASS Display..................................................................................................................18241
No SERVICE Display..................................................................................................................18241
Other Trouble Symptom...............................................................................................................18242
MID Circuit.........................................................................................................................18243
Harness Connector Faces.............................................................................................................18244
8D WIRING SYSTEM............................................................................................................................18245
Fuse, Relay and Diode...................................................................................................................18246
Relay / Fuse Box Location...........................................................................................................18246
Relay / Fuse Box (Instrument Panel).................................................................................................18247
Relay / Fuse Box (Engine Room)......................................................................................................18248
Circuit Diagram.........................................................................................................................18249
Fuse Block Circuit..................................................................................................................18249
Ground Location (Engine Room).......................................................................................................18250
Ground Location (Cabin).............................................................................................................18251
Starter and Generator...............................................................................................................18252
PCM-1...............................................................................................................................18253
PCM-2...............................................................................................................................18254
Headlight and Fog Light.............................................................................................................18255
Turn, Hazard, Stop, Back Up, Horn and A/T Shift Lock................................................................................18256
Dome Light, Luggage Room Light, Courtesy Light, Spot Light, and Warning Buzzer......................................................18257
Power Window and Door Lock..........................................................................................................18258
Alarm and Relay Control Unit........................................................................................................18259
Rear Wiper/Washer and Rear Defogger.................................................................................................18260
Audio, Clock, Cigarette Lighter and ACC Socket......................................................................................18261
MID.................................................................................................................................18262
Door Mirror.........................................................................................................................18263
Meter...............................................................................................................................18264
Anti-theft with Keyless Entry.......................................................................................................18265
Air Conditioning....................................................................................................................18266
ABS.................................................................................................................................18267
SRS–Air Bag.........................................................................................................................18268
Intelligent Suspension..............................................................................................................18269
T.O.D...............................................................................................................................18270
Sunroof.............................................................................................................................18271
Illumination Light..................................................................................................................18272
Windshield Wiper and Washer.........................................................................................................18273
Power Seat..........................................................................................................................18274
Seat Heater.........................................................................................................................18275
8E METER AND GAUGE..........................................................................................................................18276
Service Precaution......................................................................................................................18276
General Description.....................................................................................................................18276
Meter Assembly..........................................................................................................................18277
General Description.....................................................................................................................18277
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights..................................................18277
Table for Meter/Gauge Connector Terminal Connections................................................................................18279
Removal.............................................................................................................................18281
Installation........................................................................................................................18281
Warning Light Bulb and Indicator Light Bulb.........................................................................................18281
Removal.............................................................................................................................18281
Installation........................................................................................................................18281
A/T Shift Indicator Light Bulb..........................................................................................................18282
Removal.............................................................................................................................18282
Installation........................................................................................................................18283
Vehicle Speed Sensor....................................................................................................................18284
Removal.............................................................................................................................18284
Installation........................................................................................................................18284
Fuel Tank Unit..........................................................................................................................18284
Removal.............................................................................................................................18284
Main Data and Specifications............................................................................................................18285
8F BODY STRUCTURE...........................................................................................................................18286
Service Precaution......................................................................................................................18287
Frame...................................................................................................................................18287
General Description.....................................................................................................................18287
Frame Dimensions........................................................................................................................18288
General Description (Bumper)............................................................................................................18289
Front Bumper............................................................................................................................18289
Parts Location..........................................................................................................................18289
Removal.................................................................................................................................18290
Installation............................................................................................................................18291
Rear Bumper.............................................................................................................................18292
Parts Location..........................................................................................................................18292
Removal.................................................................................................................................18293
Installation............................................................................................................................18294
General Description (Sheet Metal).......................................................................................................18295
Engine Hood.............................................................................................................................18295
Parts Location..........................................................................................................................18295
Removal.................................................................................................................................18296
Installation............................................................................................................................18296
Engine Hood Lock........................................................................................................................18298
Parts Location..........................................................................................................................18298
Removal.................................................................................................................................18298
Installation............................................................................................................................18299
Front Fender Panel......................................................................................................................18300
Parts Location..........................................................................................................................18300
Removal.................................................................................................................................18301
Installation............................................................................................................................18301
Body Mounting...........................................................................................................................18303
Parts Location..........................................................................................................................18303
Tightening Torque.......................................................................................................................18303
Body Dimension..........................................................................................................................18304
Front Section...........................................................................................................................18304
Room Section (Front Side)...............................................................................................................18307
Room Section (Rear Side)................................................................................................................18309
Rear Section............................................................................................................................18311
Side Body Section (Front side)..........................................................................................................18313
Side Body Section (Rear side)...........................................................................................................18315
General Description (Body)..............................................................................................................18317
Instrument Panel Assembly...............................................................................................................18317
Parts Location..........................................................................................................................18317
Removal.................................................................................................................................18318
Installation............................................................................................................................18319
Front Door Assembly.....................................................................................................................18320
Parts Location..........................................................................................................................18320
Removal.................................................................................................................................18320
Installation............................................................................................................................18321
Rear Door Assembly......................................................................................................................18322
Parts Location..........................................................................................................................18322
Removal.................................................................................................................................18322
Installation............................................................................................................................18323
Front Window Regulator, Glass and Glass Run.............................................................................................18324
Parts Location..........................................................................................................................18324
Removal.................................................................................................................................18325
Installation............................................................................................................................18326
Rear Window Regulator, Glass and Glass Run..............................................................................................18327
Parts Location..........................................................................................................................18327
Removal.................................................................................................................................18328
Installation............................................................................................................................18330
Tailgate................................................................................................................................18331
Parts Location..........................................................................................................................18331
Removal.................................................................................................................................18332
Installation............................................................................................................................18333
Spare Tire Hanger.......................................................................................................................18334
Parts Location..........................................................................................................................18334
Removal.................................................................................................................................18335
Installation............................................................................................................................18335
Windshield..............................................................................................................................18336
Parts Location..........................................................................................................................18336
Removal.................................................................................................................................18336
Installation............................................................................................................................18337
Rear Quarter Glass......................................................................................................................18340
Parts Location..........................................................................................................................18340
Removal.................................................................................................................................18340
Installation............................................................................................................................18341
Tailgate Glass..........................................................................................................................18342
Parts Location..........................................................................................................................18342
Removal.................................................................................................................................18342
Installation............................................................................................................................18343
Main Data and Specifications............................................................................................................18344
8G SEATS....................................................................................................................................18348
Service Precaution......................................................................................................................18348
Front Seat Assembly.....................................................................................................................18349
Front Seat Assembly and Associated Parts............................................................................................18349
Removal.............................................................................................................................18349
Installation........................................................................................................................18350
Power Seat Assembly.....................................................................................................................18351
Power Seat Assembly and Associated Parts............................................................................................18351
Removal.............................................................................................................................18352
Installation........................................................................................................................18353
Rear Seat Assembly......................................................................................................................18354
Rear Seat Cushion Assembly and Associated Parts.....................................................................................18354
Removal.............................................................................................................................18355
Installation........................................................................................................................18355
Rear Seat Back Assembly and Associated Parts........................................................................................18356
Removal.............................................................................................................................18356
Installation........................................................................................................................18357
Main Data and Specifications............................................................................................................18358
8H SECURITY AND LOCKS.......................................................................................................................18360
Service Precaution......................................................................................................................18360
Front Door Lock Assembly................................................................................................................18361
Front Door Lock Assembly and Associated Parts.......................................................................................18361
Removal.............................................................................................................................18361
Installation........................................................................................................................18363
Front Outside Handle....................................................................................................................18364
Front Outside Handle and Associated Parts...........................................................................................18364
Removal.............................................................................................................................18364
Installation........................................................................................................................18364
Rear Door Lock Assembly.................................................................................................................18365
Rear Door Lock Assembly and Associated Parts........................................................................................18365
Removal.............................................................................................................................18365
Installation........................................................................................................................18367
Rear Outside Handle.....................................................................................................................18368
Rear Outside Handle and Associated Parts............................................................................................18368
Removal.............................................................................................................................18368
Installation........................................................................................................................18368
Tailgate Lock and Outside Handle........................................................................................................18369
Tailgate Lock, Outside Handle and Associated Parts..................................................................................18369
Removal.............................................................................................................................18369
Installation........................................................................................................................18370
Key.....................................................................................................................................18371
Key Coding..........................................................................................................................18371
Key Styles..........................................................................................................................18371
Power Door Lock System..................................................................................................................18372
General Description.................................................................................................................18372
Door Lock Key Switch................................................................................................................18372
Front Door Lock Actuator............................................................................................................18372
Rear Door Lock Actuator.............................................................................................................18372
Tailgate Lock Actuator..............................................................................................................18372
Anti-Theft System.......................................................................................................................18373
General Description.................................................................................................................18373
Anti‐Theft & Keyless Entry Control-ler..............................................................................................18373
Anti‐Theft Indicator................................................................................................................18373
Anti‐Theft Horn.....................................................................................................................18373
Engine Hood Switch..................................................................................................................18374
Anti‐theft & Keyless Entry Control Unit/Transmitter Replacement.....................................................................18374
Keyless Entry System....................................................................................................................18375
ID Code Check.......................................................................................................................18377
Main Data and Specifications............................................................................................................18378
8I SUNROOF/CONVERTIBLE TOP.................................................................................................................18379
Service Precaution......................................................................................................................18379
Sunroof Glass...........................................................................................................................18380
Sunroof Glass and Associated Parts..................................................................................................18380
Removal.............................................................................................................................18380
Installation........................................................................................................................18381
Sunroof Deflector.......................................................................................................................18381
Removal.............................................................................................................................18381
Installation........................................................................................................................18381
Sunshade................................................................................................................................18382
Disassembled View...................................................................................................................18382
Removal.............................................................................................................................18382
Installation........................................................................................................................18383
Sunroof Frame Complete Assembly.........................................................................................................18384
Sunroof Frame Complete Assembly and Associated Parts................................................................................18384
Removal.............................................................................................................................18384
Installation........................................................................................................................18385
Sunroof Switch..........................................................................................................................18385
Removal.............................................................................................................................18385
Installation........................................................................................................................18385
Sunroof Control Unit....................................................................................................................18386
Removal.............................................................................................................................18386
Installation........................................................................................................................18386
Sunroof Motor...........................................................................................................................18386
Removal.............................................................................................................................18386
Installation........................................................................................................................18386
Main Data and Specifications............................................................................................................18387
8J EXTERIOR / INTERIOR TRIM.................................................................................................................18388
Service Precaution......................................................................................................................18389
Consoles................................................................................................................................18390
Consoles and Associated Parts.......................................................................................................18390
Removal.............................................................................................................................18390
Installation........................................................................................................................18391
Front Door Trim Panel...................................................................................................................18391
Front Door Trim Panel and Associated Parts..........................................................................................18391
Removal.............................................................................................................................18392
Installation........................................................................................................................18392
Rear Door Trim Panel....................................................................................................................18393
Rear Door Trim Panel and Associated Parts...........................................................................................18393
Removal.............................................................................................................................18394
Installation........................................................................................................................18394
Door Mirror Assembly....................................................................................................................18395
Removal.............................................................................................................................18395
Installation........................................................................................................................18395
Interior Mirror Assembly................................................................................................................18395
Removal.............................................................................................................................18395
Installation........................................................................................................................18395
Interior Trim Panels....................................................................................................................18396
Interior Trim Panels and Associated Parts...........................................................................................18396
Removal.............................................................................................................................18396
Installation........................................................................................................................18398
Headlining..............................................................................................................................18399
Parts Location......................................................................................................................18399
Removal.............................................................................................................................18399
Installation........................................................................................................................18400
Overhead Console........................................................................................................................18401
Parts Location (W/O Sunroof)........................................................................................................18401
Removal.............................................................................................................................18401
Installation........................................................................................................................18401
Parts Location (W/ Sunroof).........................................................................................................18402
Removal.............................................................................................................................18402
Installation........................................................................................................................18402
Wheel Arch Cover........................................................................................................................18403
Wheel Arch Cover and Associated Parts...............................................................................................18403
Removal.............................................................................................................................18403
Installation........................................................................................................................18403
Locker Cover............................................................................................................................18404
Locker Cover and Associated Parts...................................................................................................18404
Removal.............................................................................................................................18404
Installation........................................................................................................................18404
Fuel Filler Door........................................................................................................................18405
Parts Location......................................................................................................................18405
Removal.............................................................................................................................18405
Installation........................................................................................................................18405
Roof Moulding...........................................................................................................................18406
Parts Location......................................................................................................................18406
Removal.............................................................................................................................18406
Installation........................................................................................................................18406
Power Door Mirror System................................................................................................................18407
General Description.....................................................................................................................18407
Power Window System.................................................................................................................18408
General Description.....................................................................................................................18408
Power Window Switch Driver Seat Side................................................................................................18408
Power Window Motor..................................................................................................................18409
Main Data and Specifications............................................................................................................18410
Sec.9 RESTRAINTS..............................................................................................................................18411
9A SEAT BELT SYSTEM........................................................................................................................18411
Service Precaution......................................................................................................................18411
Front Seat Belt.........................................................................................................................18412
Front Seat Belt and Associated Parts................................................................................................18412
Removal.............................................................................................................................18412
Inspection..........................................................................................................................18413
Installation........................................................................................................................18414
Rear Seat Belt..........................................................................................................................18415
Rear Seat Belt and Associated Parts.................................................................................................18415
Removal.............................................................................................................................18415
Inspection..........................................................................................................................18416
Installation........................................................................................................................18416
Rear Center Seat Belt / Buckle Assembly.................................................................................................18418
Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................18418
Removal.............................................................................................................................18418
Installation........................................................................................................................18418
Child Seat Tether Anchorage Bracket (Child Restraint)...................................................................................18419
Child Seat Tether Anchorage Bracket and Associated Parts............................................................................18419
Removal.............................................................................................................................18419
Installation........................................................................................................................18419
Child Seat Lower Anchorage Striker......................................................................................................18420
Child Seat Lower Anchorage Striker and Associated Parts.............................................................................18420
Removal.............................................................................................................................18420
Installation........................................................................................................................18421
Main Data and Specifications............................................................................................................18422
9J SUPPLEMENTAL RESTRAINT SYSTEM (SRS).....................................................................................................18424
Service Precaution......................................................................................................................18425
General Description.....................................................................................................................18425
Restraint Devices...................................................................................................................18425
System Description..................................................................................................................18426
SRS Component and Wiring Location View..............................................................................................18427
Component Description...................................................................................................................18427
SDM (Sensing and Diagnostic Module).................................................................................................18427
“Air Bag” Warning Lamp..............................................................................................................18428
SRS Coil Assembly...................................................................................................................18428
Air Bag Assemblies..................................................................................................................18428
Steering Column.....................................................................................................................18429
Knee Bolster........................................................................................................................18429
Definition..............................................................................................................................18429
Diagnosis...............................................................................................................................18430
Diagnostic Trouble Codes............................................................................................................18430
Scan Tool Diagnostics...............................................................................................................18430
SRS Connector Body Face Views...........................................................................................................18431
Repairs and Inspections Required After an Accident......................................................................................18431
Accident With Deployment ‐ Component Replacement and Inspections....................................................................18432
Accident With or Without Deployment-Component Inspection............................................................................18432
SDM Replacement Guidelines..........................................................................................................18432
Wiring Damage.......................................................................................................................18432
SRS Connector (Plastic Body And Terminal Metal Pin) Damage..........................................................................18432
SRS Wire Pigtail Damage.............................................................................................................18432
On‐Vehicle Service......................................................................................................................18432
Service Precautions.................................................................................................................18432
Disabling The SRS...................................................................................................................18432
Enabling The SRS....................................................................................................................18432
Handling / Installation / Diagnosis.................................................................................................18433
Air Bag Assembly Handling / Shipping / Scrapping........................................................................................18433
Live (Undeployed) Air Bag Assembly..................................................................................................18433
Air Bag Assembly Shipping Procedure For Live (Undeployed) Air Bag Assemblies........................................................18434
Deployed Air Bag Assembly...........................................................................................................18434
Air Bag Assembly Scrapping Procedure................................................................................................18434
Deployment Outside Vehicle (Driver Air Bag Assembly)................................................................................18434
Deployment Outside Vehicle (Passenger Air Bag Assembly).............................................................................18436
Deployment Inside Vehicle (Vehicle Scrapping Procedure).............................................................................18438
Deployed Air Bag Assembly Handling..................................................................................................18441
Special Tools...........................................................................................................................18441
J‐41433 SRS Driver/Passenger Load Tool..............................................................................................18441
J-39200 DVM.........................................................................................................................18442
Scan Tool...........................................................................................................................18442
J‐35616‐A Connector Test Adapter Kit................................................................................................18442
J‐42986 SRS Deployment Tool.........................................................................................................18442
J‐42987 SRS Adapter For Load Tool...................................................................................................18443
J‐41497 SRS Deployment Fixture......................................................................................................18443
Tech 2 Scan Tool....................................................................................................................18444
DTC Modes...........................................................................................................................18447
Plottong Snapshot Graph.................................................................................................................18447
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)......................................................18448
Flow Chart for Snapshot Replay (Plotting Graph).....................................................................................18449
Service Precaution......................................................................................................................18450
Disabling The SRS...................................................................................................................18450
Enabling The SRS....................................................................................................................18450
Handling / Installation / Diagnosis.................................................................................................18450
Inspections Required After An Accident..............................................................................................18450
Sensing and Diagnostic Module (SDM).....................................................................................................18451
Service Precautions.................................................................................................................18451
Removal.............................................................................................................................18451
Installation........................................................................................................................18452
Driver Air Bag Assembly.................................................................................................................18452
Service Precautions.................................................................................................................18452
Removal.............................................................................................................................18452
Installation........................................................................................................................18453
Steering Wheel..........................................................................................................................18453
Service Precautions.................................................................................................................18453
Removal.............................................................................................................................18453
Installation........................................................................................................................18454
SRS Coil Assembly.......................................................................................................................18455
Service Precaution..................................................................................................................18455
Removal.............................................................................................................................18455
Installation........................................................................................................................18455
Steering Column.........................................................................................................................18457
Service Precaution..................................................................................................................18457
Removal.............................................................................................................................18457
Installation........................................................................................................................18458
Passenger Air Bag Assembly..............................................................................................................18459
Service Precaution..................................................................................................................18459
Removal.............................................................................................................................18459
Installation........................................................................................................................18459
9J1 SRS CONTROL SYSTEM......................................................................................................................18460
Service Precaution......................................................................................................................18460
Diagnostic Procedures...................................................................................................................18461
Diagnostic Codes....................................................................................................................18461
How To Read Trouble Codes...........................................................................................................18461
How To Clear Trouble Codes..........................................................................................................18461
Scan Tool Diagnostics...............................................................................................................18461
Basic Knowledge Required............................................................................................................18461
Basic Electrical Circuits...........................................................................................................18461
“Flash Code” Diagnostics............................................................................................................18462
System Schematic........................................................................................................................18462
SRS Diagnostic System Check.............................................................................................................18463
Circuit Description.................................................................................................................18463
Notes On System Check Chart:........................................................................................................18463
Diagnostic Aids:....................................................................................................................18463
Chart A SDM Integrity Check.............................................................................................................18465
Chart B “AIR BAG” Warning Lamp Comes “ON” Steady........................................................................................18467
Chart C “AIR BAG” Warning Lamp Does Not Comes “ON” Steady...............................................................................18469
DTC 15 Passenger Deployment Loop Resistance High........................................................................................18472
DTC 16 Passenger Deployment Loop Resistance Low.........................................................................................18475
DTC 17 Passenger Deployment Loop Open...................................................................................................18478
DTC 18 Passenger Deployment Loop Short To Ground........................................................................................18480
DTC 19 Passenger Deployment Loop Short To Voltage.......................................................................................18482
DTC 21 Driver Deployment Loop Resistance High...........................................................................................18484
DTC 22 Driver Deployment Loop Resistance Low............................................................................................18487
DTC 24 Driver Deployment Loop Short To Ground...........................................................................................18490
DTC 25 Driver Deployment Loop Short To Voltage..........................................................................................18492
DTC 26 Driver Deployment Loop Open......................................................................................................18495
DTC 51 Deployment Event Commanded.......................................................................................................18498
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range..................................................18500
DTC 61 Warning Lamp Circuit Failure.....................................................................................................18502
DTC 71 Internal SDM Fault...............................................................................................................18504
Sec.10 CONTROL SYSTEM..........................................................................................................................18506
10A. CRUISE CONTROL SYSTEM..................................................................................................................18506
Service Precaution......................................................................................................................18506
General Description.....................................................................................................................18506
Brake Switch............................................................................................................................18507
Removal and Installation............................................................................................................18507
Adjustment..........................................................................................................................18507
Powertrain Control Module (PCM).........................................................................................................18508
Removal and Installation............................................................................................................18508
Mode Switch.............................................................................................................................18508
Removal and Installation............................................................................................................18508
Cruise Control Main Switch..............................................................................................................18508
Removal.............................................................................................................................18508
Installation........................................................................................................................18508
Cruise Control Switch (Combination Switch)..............................................................................................18508
Removal and Installation............................................................................................................18508
Diagnosis...............................................................................................................................18509
SECURITY AND LOCKS......................................................................................................................18360
(UX) TROOPER........................................................................................................................................18510
Sec.0 GENERAL INFORMATION.......................................................................................................................18511
0A GENERAL INFORMATION......................................................................................................................18511
General Repair Instruction..............................................................................................................18511
Illustration Arrows.....................................................................................................................18512
Identification..........................................................................................................................18513
Theft Prevention Standard...............................................................................................................18516
Lifting Instructions....................................................................................................................18522
Standard Bolts Torque Specifications....................................................................................................18524
Abbreviations Charts....................................................................................................................18525
Service Parts Identification Plate......................................................................................................18526
0B MAINTENANCE AND LUBRICATION..............................................................................................................18527
Maintenance Schedule List...............................................................................................................18527
Explanation of Complete Vehicle Maintenance Schedule....................................................................................18531
Recommended Fluids and Lubricants...................................................................................................18534
Lubricant Viscosity Chart...............................................................................................................18535
Recommended Liquid Gasket...........................................................................................................18537
Recommended Thread Locking Agents...................................................................................................18537
Maintenance Service Data................................................................................................................18538
Sec.1 HEATING, VENTILATION AND AIR CONDITIONING.................................................................................................18539
1A HVAC SYSTEMS.............................................................................................................................18539
Service Precaution......................................................................................................................18541
Heating and Ventilation System..........................................................................................................18541
General Description.....................................................................................................................18541
Wiring Diagram......................................................................................................................18546
Diagnosis...........................................................................................................................18547
Individual Inspection...............................................................................................................18550
Heater Unit.............................................................................................................................18552
Heater Unit and Associated Parts....................................................................................................18552
Removal.............................................................................................................................18553
Installation........................................................................................................................18553
Heater Core and / or Mode Door..........................................................................................................18554
Disassembled View...................................................................................................................18554
Removal.............................................................................................................................18554
Inspection..........................................................................................................................18555
Installation........................................................................................................................18555
Heater Mode Control Link Unit...........................................................................................................18556
Disassembled View...................................................................................................................18556
Removal.............................................................................................................................18556
Installation........................................................................................................................18557
Heater Temperature Control Link Unit....................................................................................................18557
Disassembled View...................................................................................................................18557
Removal.............................................................................................................................18557
Installation........................................................................................................................18557
Blower Assembly.........................................................................................................................18558
Blower Assembly and Associated Parts................................................................................................18558
Removal.............................................................................................................................18558
Installation........................................................................................................................18559
Blower Link Unit and / or Mode door.....................................................................................................18559
Disassembled View...................................................................................................................18559
Removal.............................................................................................................................18559
Installation........................................................................................................................18560
Blower Motor............................................................................................................................18561
Blower Motor and Associated Parts...................................................................................................18561
Removal.............................................................................................................................18561
Installation........................................................................................................................18561
Rear Heater Duct, Defroster Nozzle and Ventilation Duct.................................................................................18562
Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts...........................................................18562
Removal.............................................................................................................................18562
Installation........................................................................................................................18563
Center and / or Drive Side Vent.........................................................................................................18563
Center Vent, Drive Side Vent and Associated Parts...................................................................................18563
Removal.............................................................................................................................18563
Installation........................................................................................................................18563
Control Lever Assembly and / or Control Cable...........................................................................................18564
Control Lever Assembly, Control Cable and Associated Parts..........................................................................18564
Removal.............................................................................................................................18564
Installation........................................................................................................................18566
Control Panel Illumination Bulb.........................................................................................................18567
Control Panel Illumination Bulb and Associated Parts................................................................................18567
Removal.............................................................................................................................18567
Installation........................................................................................................................18567
Resistor................................................................................................................................18568
Resistor and Associated Parts.......................................................................................................18568
Removal.............................................................................................................................18568
Installation........................................................................................................................18568
Air Conditioning System.................................................................................................................18569
General Description.................................................................................................................18569
Diagnosis...........................................................................................................................18577
Individual Inspection...............................................................................................................18585
General Repair Procedure............................................................................................................18586
Compressor Assembly.....................................................................................................................18594
Compressor Assembly and Associated Parts (6VE1).....................................................................................18594
Removal.............................................................................................................................18594
Installation........................................................................................................................18595
New Compressor Installation.........................................................................................................18595
Condenser Assembly......................................................................................................................18596
Condenser Assembly and Associated Parts.............................................................................................18596
Removal.............................................................................................................................18596
Installation........................................................................................................................18596
Receiver / Drier........................................................................................................................18597
Receiver / Drier and Associated Parts...............................................................................................18597
Removal.............................................................................................................................18597
Installation........................................................................................................................18597
Pressure Switch.........................................................................................................................18598
Pressure Switch and Associated Parts................................................................................................18598
Removal.............................................................................................................................18598
Installation........................................................................................................................18598
Evaporator Assembly.....................................................................................................................18599
Evaporator Assembly and Associated Parts............................................................................................18599
Removal.............................................................................................................................18599
Installation........................................................................................................................18600
Electronic Thermostat, Evaporator Core and/or Expansion Valve...........................................................................18600
Disassembled View...................................................................................................................18600
Removal.............................................................................................................................18601
Installation........................................................................................................................18601
Air Conditioning Switch and Illumination Bulb...........................................................................................18602
Air Conditioning Switch, Illumination Bulb and Associated Parts.....................................................................18602
Removal.............................................................................................................................18602
Installation........................................................................................................................18602
Refrigerant Line........................................................................................................................18603
Refrigerant Line and Associated Parts...............................................................................................18603
Removal.............................................................................................................................18603
Installation........................................................................................................................18604
Main Data And Specifications............................................................................................................18605
Compressor..............................................................................................................................18608
Service Precaution..................................................................................................................18608
General Description.................................................................................................................18608
Diagnosis...........................................................................................................................18609
Magnetic Clutch Assembly (DKV-14G Type).................................................................................................18610
Parts Location View.................................................................................................................18610
Removal.............................................................................................................................18610
Inspection and Repair...............................................................................................................18612
Installation........................................................................................................................18612
Compressor Oil..........................................................................................................................18614
Oil Specification...................................................................................................................18614
Handling of Oil.....................................................................................................................18614
Compressor Oil Check................................................................................................................18614
Checking and Adjusting Oil Quantity for Used Compressor.............................................................................18614
Checking and Adjusting for Compressor Replacement...................................................................................18614
Contamination of Compressor Oil.....................................................................................................18615
Oil Return Operation................................................................................................................18615
Replacement of Component Parts......................................................................................................18615
Main Data and Specifications........................................................................................................18616
Special Tools.......................................................................................................................18618
Automatic Air Conditioning System.......................................................................................................18619
General Description.....................................................................................................................18619
Full Automatic Air Conditioner Parts Configuration..................................................................................18619
Refrigerant Line and Associated Parts...............................................................................................18620
Circuit Diagram.....................................................................................................................18621
Functions and Features..............................................................................................................18626
Automatic Air Conditioner Block Diagram.............................................................................................18627
Control Panel Layout................................................................................................................18628
Air Control Functions...............................................................................................................18629
Operation and Functions of Control Panel Switches...................................................................................18630
Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System...................................18632
Overview of Automatic Control of Automatic Air Conditioner..........................................................................18636
Troubleshooting.........................................................................................................................18640
Troubleshooting, Its Overview and Procedures........................................................................................18640
Auto Air Conditioner Control Unit Power Supply Diagnosis............................................................................18641
Performance and Movement checklist for Automatic Air Conditioner Related Parts......................................................18643
Troubleshooting With Self-Diagnosis Function........................................................................................18645
Inspection By Failed Location...........................................................................................................18649
Inspection of the Sensors...........................................................................................................18649
Inspection of the Intake Actuator System............................................................................................18653
Inspection of the Mix Actuator System...............................................................................................18656
Inspection of the Mode Actuator System..............................................................................................18659
Inspection of the Fan Motor System..................................................................................................18662
Inspection of the Magnetic Clutch System............................................................................................18664
Condenser Fan Diagnosis.............................................................................................................18667
Individual Inspection...............................................................................................................18670
On-Vehicle Service......................................................................................................................18673
Power Transistor....................................................................................................................18673
Removal.............................................................................................................................18673
Installation........................................................................................................................18673
Automatic Heater/Air Conditioner Control Unit.......................................................................................18673
Removal.............................................................................................................................18673
Installation........................................................................................................................18673
In Car Sensor.......................................................................................................................18674
Removal.............................................................................................................................18674
Installation........................................................................................................................18674
Ambient Sensor......................................................................................................................18674
Removal.............................................................................................................................18674
Installation........................................................................................................................18674
Sun Sensor..........................................................................................................................18675
Removal.............................................................................................................................18675
Installation........................................................................................................................18675
Duct Sensor.........................................................................................................................18675
Removal.............................................................................................................................18675
Installation........................................................................................................................18675
Mode Actuator.......................................................................................................................18676
Removal.............................................................................................................................18676
Installation........................................................................................................................18676
Mix Actuator........................................................................................................................18676
Removal.............................................................................................................................18676
Installation........................................................................................................................18676
Intake Actuator.....................................................................................................................18677
Removal.............................................................................................................................18677
Installation........................................................................................................................18677
Sec.2 STEERING..................................................................................................................................18678
2A POWER ASSISTED SYSTEM....................................................................................................................18678
Service Precaution......................................................................................................................18679
General Description.....................................................................................................................18679
Diagnosis...............................................................................................................................18682
Power Steering System Test..............................................................................................................18688
Maintenance.............................................................................................................................18689
Fluid Level.............................................................................................................................18689
Bleeding The Power Steering System......................................................................................................18689
Bleeding Procedure......................................................................................................................18689
Flushing The Power Steering System......................................................................................................18689
Steering Wheel Free Play Adjustment.....................................................................................................18690
Front End Alignment Inspection and Adjustment...........................................................................................18690
Main Data and Specifications............................................................................................................18695
Special Tools...........................................................................................................................18696
Power Steering Gear.....................................................................................................................18697
Power Steering Gear and Associated Parts............................................................................................18697
Removal.............................................................................................................................18697
Installation........................................................................................................................18698
Steering Gear Disassembled View.....................................................................................................18699
Disassembly.........................................................................................................................18700
Inspection and Repair...............................................................................................................18701
Reassembly..........................................................................................................................18702
Main Data and Specifications........................................................................................................18704
Power Steering Pump.....................................................................................................................18705
Power Steering Pump and Associated Parts............................................................................................18705
Removal.............................................................................................................................18705
Installation........................................................................................................................18706
Power Steering Pump Disassembled View...............................................................................................18707
Disassembly.........................................................................................................................18707
Inspection and Repair...............................................................................................................18708
Reassembly..........................................................................................................................18709
1Main Data and Specifications.......................................................................................................18710
Center Track Rod Assembly...............................................................................................................18711
Center Track Rod Assembly and Associated Parts......................................................................................18711
Removal.............................................................................................................................18712
Inspection and Repair...............................................................................................................18712
Installation........................................................................................................................18712
Outer Track Rod Assembly................................................................................................................18713
Outer Track Rod Assembly and Associated Parts.......................................................................................18713
Removal.............................................................................................................................18714
Inspection and Repair...............................................................................................................18714
Installation........................................................................................................................18715
Relay Lever.............................................................................................................................18716
Relay Lever and Associated Parts....................................................................................................18716
Removal.............................................................................................................................18716
Installation........................................................................................................................18717
Steering Linkage and Associated Parts...................................................................................................18718
Main Data and Specifications........................................................................................................18718
Special Tools.......................................................................................................................18719
Supplemental Restraint System Steering Wheel & Column...................................................................................18720
Service Precaution..................................................................................................................18720
SRS Connectors......................................................................................................................18720
Inflator Module.........................................................................................................................18722
Inflator Module and Associated Parts................................................................................................18722
Removal.............................................................................................................................18722
Inspection and Repair...............................................................................................................18723
Installation........................................................................................................................18723
Steering Wheel..........................................................................................................................18724
Steering Wheel and Associated Parts.................................................................................................18724
Removal.............................................................................................................................18724
Installation........................................................................................................................18726
Combination Switch......................................................................................................................18727
Combination Switch and Associated Parts.............................................................................................18727
Removal.............................................................................................................................18727
Installation........................................................................................................................18729
Lock Cylinder...........................................................................................................................18731
Lock Cylinder and Associated Parts..................................................................................................18731
Removal.............................................................................................................................18731
Installation........................................................................................................................18733
System Inspection...................................................................................................................18734
Steering Column.........................................................................................................................18735
Steering Column and Associated Parts................................................................................................18735
Removal.............................................................................................................................18735
Inspection..........................................................................................................................18737
Installation........................................................................................................................18739
System Inspection...................................................................................................................18740
Supplemental Restraint System Steering Wheel & Column and Associated Parts..............................................................18741
Main Data and Specifications........................................................................................................18741
Special Tools.......................................................................................................................18742
Sec.3 SUSPENSION................................................................................................................................18743
3C FRONT SUSPENSION.........................................................................................................................18743
Service Precaution......................................................................................................................18743
General Description.....................................................................................................................18744
General Diagnosis.......................................................................................................................18745
Shock Absorber..........................................................................................................................18748
Shock Absorber and Associated Parts.................................................................................................18748
Removal.............................................................................................................................18748
Inspection and Repair...............................................................................................................18748
Installation........................................................................................................................18748
Stabilizer Bar..........................................................................................................................18749
Stabilizer Bar and Associated Parts.................................................................................................18749
Removal.............................................................................................................................18749
Inspection and Repair...............................................................................................................18749
Installation........................................................................................................................18749
Torsion Bar.............................................................................................................................18750
Torsion Bar and Associated Parts....................................................................................................18750
Removal.............................................................................................................................18750
Inspection and Repair...............................................................................................................18751
Installation........................................................................................................................18751
Knuckle.................................................................................................................................18753
Knuckle and Associated Parts........................................................................................................18753
Removal.............................................................................................................................18753
Inspection and Repair...............................................................................................................18754
Installation........................................................................................................................18754
Upper Control Arm.......................................................................................................................18756
Upper Control Arm and Associated Parts..............................................................................................18756
Removal.............................................................................................................................18756
Inspection and Repair...............................................................................................................18757
Installation........................................................................................................................18758
Lower Control Arm.......................................................................................................................18760
Lower Control Arm and Associated Parts..............................................................................................18760
Removal.............................................................................................................................18760
Inspection and Repair...............................................................................................................18761
Installation........................................................................................................................18762
Upper Ball Joint........................................................................................................................18763
Upper Ball Joint and Associated Parts...............................................................................................18763
Removal.............................................................................................................................18763
Inspection and Repair...............................................................................................................18764
Installation........................................................................................................................18764
Lower Ball Joint........................................................................................................................18765
Lower Ball Joint and Associated Parts...............................................................................................18765
Removal.............................................................................................................................18765
Inspection and Repair...............................................................................................................18766
Installation........................................................................................................................18766
Main Data and Specifications............................................................................................................18767
Special Tools...........................................................................................................................18768
3D REAR SUSPENSION..........................................................................................................................18769
Service Precaution......................................................................................................................18769
General Description.....................................................................................................................18770
Coil Spring.............................................................................................................................18771
Coil Spring and Associated Parts....................................................................................................18771
Removal.............................................................................................................................18771
Inspection and Repair...............................................................................................................18772
Installation........................................................................................................................18772
Shock Absorber..........................................................................................................................18773
Shock Absorber and Associated Parts.................................................................................................18773
Removal.............................................................................................................................18773
Inspection and Repair...............................................................................................................18773
Installation........................................................................................................................18773
Trailing Link...........................................................................................................................18774
Trailing Link and Associated Parts..................................................................................................18774
Removal.............................................................................................................................18774
Inspection and Repair...............................................................................................................18774
Installation........................................................................................................................18775
Center Link.............................................................................................................................18776
Center Link and Associated Parts....................................................................................................18776
Removal.............................................................................................................................18776
Inspection and Repair...............................................................................................................18776
Installation........................................................................................................................18777
Lateral Rod.............................................................................................................................18778
Lateral Rod and Associated Parts....................................................................................................18778
Removal.............................................................................................................................18778
Inspection and Repair...............................................................................................................18778
Installation........................................................................................................................18779
Stabilizer Bar..........................................................................................................................18780
Stabilizer Bar and Associated Parts.................................................................................................18780
Removal.............................................................................................................................18780
Inspection and Repair...............................................................................................................18780
Installation........................................................................................................................18781
Main Data and Specifications............................................................................................................18782
Special Tools...........................................................................................................................18784
3E WHEEL AND TIRE SYSTEM....................................................................................................................18785
Service Precaution......................................................................................................................18785
General Description.....................................................................................................................18786
Diagnosis...............................................................................................................................18787
Wheel...................................................................................................................................18793
Wheel and Associated Parts..........................................................................................................18793
Removal.............................................................................................................................18793
Installation........................................................................................................................18793
Tire....................................................................................................................................18794
Tire Replacement....................................................................................................................18794
General Balance Procedure...............................................................................................................18794
Balancing Wheel and Tire................................................................................................................18795
Main Data and Specifications............................................................................................................18796
Sec.4 DRIVELINE/AXLE............................................................................................................................18797
4A1 DIFFERENTIAL (FRONT)....................................................................................................................18797
Service Precaution......................................................................................................................18797
Front Drive Axle........................................................................................................................18798
Diagnosis...............................................................................................................................18798
Pinion Shaft Oil Seal...................................................................................................................18799
Pinion Shaft Oil Seal and Associated Parts..........................................................................................18799
Removal.............................................................................................................................18799
Inspection and Repair...............................................................................................................18800
Installation........................................................................................................................18800
Front Drive Axle Assembly...............................................................................................................18801
Front Drive Axle Assembly and Associated Parts......................................................................................18801
Removal.............................................................................................................................18801
Installation........................................................................................................................18803
Differential Assembly...................................................................................................................18805
Disassembled View...................................................................................................................18805
Disassembly.........................................................................................................................18806
Reassembly..........................................................................................................................18808
Differential Cage Assembly..............................................................................................................18817
Disassembled View...................................................................................................................18817
Disassembly.........................................................................................................................18817
Inspection and Repair...............................................................................................................18818
Reassembly..........................................................................................................................18819
Main Data and Specifications........................................................................................................18821
Special Tools.......................................................................................................................18823
4A2 DIFFERENTIAL (REAR).....................................................................................................................18825
Service Precaution......................................................................................................................18825
General Description.....................................................................................................................18827
Diagnosis...............................................................................................................................18828
Axle Housing............................................................................................................................18829
Axle Housing and Associated Parts...................................................................................................18829
Removal.............................................................................................................................18829
Oil Seal Replacement................................................................................................................18830
Installation........................................................................................................................18830
Axle Shaft..............................................................................................................................18831
Axle Shaft and Associated Parts.....................................................................................................18831
Removal.............................................................................................................................18831
Inspection and Repair...............................................................................................................18832
Oil Seal Replacement................................................................................................................18833
Installation........................................................................................................................18833
Pinion Oil Seal.........................................................................................................................18834
Pinion Oil Seal and Associated Parts................................................................................................18834
Removal.............................................................................................................................18834
Inspection and Repair...............................................................................................................18835
Installation........................................................................................................................18835
Differential Assembly...................................................................................................................18836
Differential Assembly and Associated Parts..........................................................................................18836
Removal.............................................................................................................................18836
Installation........................................................................................................................18837
Disassembled View...................................................................................................................18838
Disassembly.........................................................................................................................18839
Reassembly..........................................................................................................................18841
Differential Cage Assembly..............................................................................................................18848
Disassembled View...................................................................................................................18848
Disassembly.........................................................................................................................18849
Inspection and Repair...............................................................................................................18849
Reassembly..........................................................................................................................18850
Limited Slip Differential...............................................................................................................18852
Disassembled View...................................................................................................................18852
Disassembly.........................................................................................................................18853
Inspection and Repair...............................................................................................................18853
Reassembly..........................................................................................................................18855
Main Data and Specifications............................................................................................................18859
Special Tools...........................................................................................................................18860
4B1 DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY).............................................................................................18863
Service Precaution......................................................................................................................18863
Shift On The Fly System.................................................................................................................18864
Outline of Shift on The Fly System..................................................................................................18864
Functions of Indicator Lamp.........................................................................................................18868
Diagnosis...........................................................................................................................18869
Front Axle Diagnosis................................................................................................................18879
Shift On The Fly Vacuum Piping And Electric Equipment...................................................................................18881
Vacuum piping diagram...............................................................................................................18881
Inspection And Repair...............................................................................................................18882
4WD Control Unit........................................................................................................................18885
4WD Control Unit Associated Parts...................................................................................................18885
Removal.............................................................................................................................18886
Installation........................................................................................................................18886
4B2 DRIVELINE CONTROL SYSTEM (TOD)..........................................................................................................18887
Service Precaution......................................................................................................................18887
General Description.....................................................................................................................18888
System Components.......................................................................................................................18890
Parts Location......................................................................................................................18890
Functions of Indicator Lamp.............................................................................................................18894
Diagnosis...............................................................................................................................18898
Basic Diagnostic Flow Chart.............................................................................................................18902
Parts Location..........................................................................................................................18903
Circuit Diagram.........................................................................................................................18904
Connector List..........................................................................................................................18907
Checking Failed Pin.....................................................................................................................18909
Checking Failed TOD Control Unit Pin....................................................................................................18912
Diagnostic Trouble Codes................................................................................................................18917
Diagnosis from Trouble Codes............................................................................................................18918
Trouble Diagnosis Depending on The Status of TOD Indicator..............................................................................18942
Diagnosis from Symptom..................................................................................................................18971
4C DRIVE SHAFT SYSTEM.......................................................................................................................18981
Service Precaution......................................................................................................................18982
General Description.....................................................................................................................18982
Diagnosis...............................................................................................................................18983
Front Hub and Disc (2WD Model)..........................................................................................................18984
Disassembled View...................................................................................................................18984
Disassembly.........................................................................................................................18984
Inspection and Repair...............................................................................................................18986
Reassembly..........................................................................................................................18986
Main Data and Specifications........................................................................................................18989
Special Tools.......................................................................................................................18990
Front Hub and Disc (4WD Model)..........................................................................................................18991
Disassembled View...................................................................................................................18991
Disassembly.........................................................................................................................18991
Inspection and Repair...............................................................................................................18992
Reassembly..........................................................................................................................18992
Main Data and Specifications........................................................................................................18996
Special Tools.......................................................................................................................18997
Front Drive Shaft Joint.................................................................................................................18998
Front Drive Shaft Joints Replacement................................................................................................18998
Front Axle Drive Shaft..................................................................................................................18999
Front Axle Drive Shaft and Associated Parts.........................................................................................18999
Disassembly.........................................................................................................................19000
Inspection and Repair...............................................................................................................19001
Bushing Replacement.................................................................................................................19001
Reassembly..........................................................................................................................19002
Shift On The Fly System.................................................................................................................19004
Shift On The Fly System and Associated Parts........................................................................................19004
Disassembly.........................................................................................................................19004
Inspection and Repair...............................................................................................................19006
Main Data and Specifications........................................................................................................19011
Special Tools.......................................................................................................................19012
Front Propeller Shaft...................................................................................................................19013
General Description.................................................................................................................19013
Front Propeller Shaft and Associated Parts..........................................................................................19014
Removal.............................................................................................................................19014
Installation........................................................................................................................19015
Disassembly (Except TOD 4×4)........................................................................................................19016
Universal Joint Disassembly.........................................................................................................19017
Inspection and Repair...............................................................................................................19018
Universal Joint Reassembly..........................................................................................................19021
Reassembly (Except TOD 4×4).........................................................................................................19022
Main Data and Specifications........................................................................................................19023
Rear Propeller Shaft....................................................................................................................19024
General Description.................................................................................................................19024
Rear Propeller Shaft and Associated Parts...........................................................................................19024
Removal.............................................................................................................................19024
Installation........................................................................................................................19025
Disassembly.........................................................................................................................19026
Universal Joint Disassembly.........................................................................................................19027
Inspection and Repair...............................................................................................................19028
Universal Joint Reassembly..........................................................................................................19029
Reassembly..........................................................................................................................19030
Main Data and Specifications........................................................................................................19031
4D1 TRANSFER CASE (STANDARD TYPE)...........................................................................................................19032
Service Precaution......................................................................................................................19032
General Description.....................................................................................................................19033
Transfer Rear Oil Seal..................................................................................................................19035
Removal.............................................................................................................................19035
Installation........................................................................................................................19035
Transfer Case Assembly..................................................................................................................19037
Removal.............................................................................................................................19037
Installation........................................................................................................................19038
Transfer Rear Case Assembly.............................................................................................................19040
Removal.............................................................................................................................19040
Installation........................................................................................................................19041
Disassembly.........................................................................................................................19044
Inspection and Repair...............................................................................................................19045
Reassembly..........................................................................................................................19045
Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)...........................................................................19047
Disassembled View...................................................................................................................19047
Disassembly.........................................................................................................................19048
Inspection and Repair...............................................................................................................19049
Reassembly..........................................................................................................................19049
Transfer Case Assembly..................................................................................................................19051
Disassembled View...................................................................................................................19051
Disassembly.........................................................................................................................19052
Inspection and Repair...............................................................................................................19054
Reassembly..........................................................................................................................19058
Main Data and Specifications............................................................................................................19064
Special Tools...........................................................................................................................19067
4D2 TRANSFER CASE (TOD).....................................................................................................................19068
Service Precaution......................................................................................................................19068
Transfer Case Assembly..................................................................................................................19069
Removal.............................................................................................................................19069
Installation........................................................................................................................19070
Transfer Rear Oil Seal..................................................................................................................19072
Transfer Rear Oil Seal and Associated Parts.........................................................................................19072
Removal.............................................................................................................................19072
Installation........................................................................................................................19072
TOD ECU.................................................................................................................................19074
Removal.............................................................................................................................19074
Installation........................................................................................................................19074
Unit Repair.............................................................................................................................19075
Inspection..........................................................................................................................19075
Transfer Case...........................................................................................................................19076
Disassembled View...................................................................................................................19076
Disassembly.........................................................................................................................19076
Reassembly..........................................................................................................................19077
Transfer Cover Assembly.................................................................................................................19079
Disassembled View...................................................................................................................19079
Disassembly.........................................................................................................................19079
Reassembly..........................................................................................................................19081
Transfer Case Assembly Clutch Pack and Clutch Cam.......................................................................................19083
Disassembled View...................................................................................................................19083
Disassembly.........................................................................................................................19083
Sprocket and Mechanical Lock............................................................................................................19085
Disassembled View...................................................................................................................19085
Disassembly.........................................................................................................................19085
Output Shafts and Shift Control Shaft...................................................................................................19087
Disassembled View...................................................................................................................19087
Disassembly.........................................................................................................................19088
Transfer Case...........................................................................................................................19090
Disassembled View...................................................................................................................19090
Disassembly.........................................................................................................................19091
Inspection and Repair...............................................................................................................19093
Transfer Case...........................................................................................................................19097
Disassembled View...................................................................................................................19097
Reassembly..........................................................................................................................19097
Output Shafts and Shift Control Shaft...................................................................................................19101
Disassembled View...................................................................................................................19101
Reassembly..........................................................................................................................19102
Sprocket and Mechanical Lock............................................................................................................19104
Disassembled View...................................................................................................................19104
Reassembly..........................................................................................................................19104
Clutch Pack and Clutch Cam..............................................................................................................19106
Disassembled View...................................................................................................................19106
Reassembly..........................................................................................................................19106
Main Data and Specifications............................................................................................................19108
Special Tools...........................................................................................................................19110
Sec.5 BRAKES....................................................................................................................................19111
5A BRAKE CONTROL SYSTEM.....................................................................................................................19111
Service Precaution......................................................................................................................19112
General Description.....................................................................................................................19113
System Components...................................................................................................................19113
Electronic Hydraulic Control Unit (EHCU)............................................................................................19113
ABS Warning Light...................................................................................................................19114
Wheel Speed Sensor..................................................................................................................19114
G-Sensor............................................................................................................................19114
Normal and Anti-lock Braking........................................................................................................19114
Brake Pedal Travel..................................................................................................................19114
Acronyms and Abbreviations..........................................................................................................19114
General Diagnosis.......................................................................................................................19115
General Information.................................................................................................................19115
ABS Service Precautions.............................................................................................................19115
Computer System Service Precautions.................................................................................................19115
General Service Precautions.........................................................................................................19115
Note on Intermittents...............................................................................................................19115
Test Driving ABS Complaint Vehicles.................................................................................................19115
“ABS” Warning Light.................................................................................................................19116
Normal Operation....................................................................................................................19116
Basic Diagnostic Flow Chart.........................................................................................................19116
Basic Inspection Procedure..........................................................................................................19117
Tech 2 Scan Tool....................................................................................................................19118
Getting Started.....................................................................................................................19119
Operating Procedure.................................................................................................................19119
Data List...............................................................................................................................19121
EHCU Connector Pin-out Checks...........................................................................................................19122
Circuit Diagram.....................................................................................................................19123
Connector List......................................................................................................................19126
Part Location.......................................................................................................................19128
Symptom Diagnosis.......................................................................................................................19129
Chart A–1 ABS Works Frequently But Vehicle Does Not Decelerate......................................................................19129
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................19130
Chart A-2 Uneven Braking Occurs While ABS Works.....................................................................................19130
Chart A-3, TA-3 The Wheels Are Locked...............................................................................................19131
Chart A-4 Brake Pedal Feed Is Abnormal..............................................................................................19131
Chart A-5,TA-5 Braking Sound (From EHCU) Is Heard While Not Braking.................................................................19132
Diagnostic Trouble Codes................................................................................................................19133
Diagnosis By “ABS” Warning Light Illumination Pattern...................................................................................19134
Diagnostic Trouble Codes (DTCs).....................................................................................................19134
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L)
is not activated.......................19137
Chart B-2 EHCU Abnormality (DTC 14).................................................................................................19137
Chart B-3 Power Voltage Drop (DTC 15)...............................................................................................19138
Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)...........................................................................19138
Chart B-5 G-Sensor Circuit (DTC 21).................................................................................................19138
Chart B-6 Abnormal Transmission Input (DTC 23)......................................................................................19139
Chart B-7 Transfer Monitor (DTC 24).................................................................................................19140
Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32)..........................................................................19140
Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35)..........................................................................19141
Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41).........................................................................19141
Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42)..............................................................................19141
Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43).........................................................................19142
Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44)..............................................................................19142
Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45).......................................................................19142
Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)............................................................................19143
Chart B-16 FL Speed Sensor Disconnection (DTC 51)...................................................................................19143
Chart B-17 FR Speed Sensor Disconnection (DTC 52)...................................................................................19144
Chart B-18 RL Speed Sensor Disconnection (DTC 53)...................................................................................19144
Chart B-19 RR Speed Sensor Disconnection (DTC 54)...................................................................................19145
Chart B-20 FL Speed Sensor Short Circuit (DTC 61)...................................................................................19146
Chart B-21 FR Speed Sensor Short Circuit (DTC 62)...................................................................................19147
Chart B-22 RL Speed Sensor Short Circuit (DTC 63)...................................................................................19148
Chart B-23 RR Speed Sensor Short Circuit (DTC 64)...................................................................................19149
Chart B-24 Sensor Signal Input Abnormality (DTC 65).................................................................................19150
Sensor Signal Abnormality Criteria using TECH 2.....................................................................................19150
Unit Inspection Procedure...............................................................................................................19151
Chart C-1-1 FL Sensor Output Inspection Procedure...................................................................................19151
Chart C-1-2 FR Sensor Output Inspection Procedure...................................................................................19152
Chart C-1-3 RL Sensor Output Inspection Procedure...................................................................................19152
Chart C-1-4 RR Sensor Output Inspection Procedure...................................................................................19153
Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)..........................................................................19153
Chart C-2 Transmission Input Inspection Procedure...................................................................................19154
Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2).....................................................................19155
Special Tools...........................................................................................................................19156
5B ANTI-LOCK BRAKE SYSTEM...................................................................................................................19157
Service Precaution......................................................................................................................19157
Electronic Hydraulic Control Unit.......................................................................................................19158
Electronic Hydraulic Control Unit and Associated Parts..............................................................................19158
Removal.............................................................................................................................19158
Installation........................................................................................................................19158
G-Sensor................................................................................................................................19159
Removal.............................................................................................................................19159
Inspection and Repair...............................................................................................................19159
Installation........................................................................................................................19159
Front Wheel Speed Sensor................................................................................................................19160
Front Wheel Speed Sensor and Associated Parts.......................................................................................19160
Removal.............................................................................................................................19160
Inspection and Repair...............................................................................................................19161
Installation........................................................................................................................19161
Rear Wheel Speed Sensor.................................................................................................................19162
Rear Wheel Speed Sensor and Associated Parts........................................................................................19162
Removal.............................................................................................................................19162
Inspection and Repair...............................................................................................................19162
Installation........................................................................................................................19162
5C POWER-ASSISTED BRAKE SYSTEM..............................................................................................................19163
Service Precaution......................................................................................................................19164
General Description.....................................................................................................................19164
Diagnosis...............................................................................................................................19167
General Diagnosis.......................................................................................................................19168
Hydraulic Brakes........................................................................................................................19171
Filling Master Cylinder Reservoir...................................................................................................19171
Deterioration of Brake Fluid........................................................................................................19171
Leakage of Brake Fluid..............................................................................................................19171
Bleeding Brake Hydraulic System.....................................................................................................19171
Flushing Brake Hydraulic System.....................................................................................................19172
Brake Pipes and Hoses...............................................................................................................19172
Brake Hose Inspection...............................................................................................................19172
Front / Rear Caliper Brake Hose.........................................................................................................19173
Front / Rear Caliper Brake Hose and Associated Parts................................................................................19173
Removal.............................................................................................................................19173
Installation........................................................................................................................19173
Rear Axle Brake Hose....................................................................................................................19174
Rear Axle Brake Hose and Associated
Parts..........................................................................................19174
Removal.............................................................................................................................19174
Installation........................................................................................................................19174
Brake Pipe..............................................................................................................................19175
Removal.............................................................................................................................19175
Installation........................................................................................................................19175
P & B (Proportioning and Bypass) Valve..................................................................................................19176
Removal.............................................................................................................................19176
Installation........................................................................................................................19176
Main Data and Specifications............................................................................................................19177
Brake Pedal.............................................................................................................................19178
Checking Pedal Height...............................................................................................................19178
Checking Pedal Travel...............................................................................................................19178
Brake Pedal and Associated Parts....................................................................................................19179
Removal.............................................................................................................................19179
Installation........................................................................................................................19179
Stoplight Switch........................................................................................................................19180
Removal.............................................................................................................................19180
Installation........................................................................................................................19180
Main Data and Specifications............................................................................................................19181
Fluid Reservoir Tank....................................................................................................................19182
Fluid Reservoir Tank and Associated Parts...........................................................................................19182
Removal.............................................................................................................................19182
Installation........................................................................................................................19182
Master Cylinder Assembly................................................................................................................19183
Master Cylinder Assembly and Associated Parts.......................................................................................19183
Removal.............................................................................................................................19183
Inspection and Repair...............................................................................................................19183
Installation........................................................................................................................19184
Main Data and Specifications........................................................................................................19185
Special Tools.......................................................................................................................19186
Vacuum Booster Assembly.................................................................................................................19187
Vacuum Booster Assembly and Associated Parts........................................................................................19187
Removal.............................................................................................................................19187
Inspection and Repair...............................................................................................................19187
Installation........................................................................................................................19188
Exterior Components.....................................................................................................................19190
Exterior Components and Associated Parts............................................................................................19190
Removal.............................................................................................................................19190
Inspection and Repair...............................................................................................................19191
Installation........................................................................................................................19191
Vacuum Booster Overhaul.................................................................................................................19191
Vacuum Booster......................................................................................................................19191
Main Data and Specifications............................................................................................................19192
Special Tools...........................................................................................................................19193
Front Disc Brake Pads...................................................................................................................19194
Front Disc Brake Pads Inspection....................................................................................................19194
Front Disc Brake Pads and Associated Parts..........................................................................................19194
Removal.............................................................................................................................19195
Installation........................................................................................................................19195
Front Disc Brake Rotor..................................................................................................................19197
Inspection..........................................................................................................................19197
Replacing Brake Rotors..............................................................................................................19197
Refinishing Brake Rotors............................................................................................................19197
Front Disc Brake Caliper Assembly.......................................................................................................19199
Front Disc Brake Caliper Assembly and Associated Parts..............................................................................19199
Removal.............................................................................................................................19199
Installation........................................................................................................................19200
Front Disc Brake Caliper................................................................................................................19202
Front Disc Brake Caliper Disassembled View..........................................................................................19202
Disassembly.........................................................................................................................19202
Inspection and Repair...............................................................................................................19203
Reassembly..........................................................................................................................19203
Main Data and Specifications........................................................................................................19205
Rear Disc Brake Pads....................................................................................................................19206
Brake Pads Inspection...............................................................................................................19206
Brake Pads and Associated Parts.....................................................................................................19206
Removal.............................................................................................................................19207
Installation........................................................................................................................19207
Rear Disc Brake Rotor...................................................................................................................19209
Inspection..........................................................................................................................19209
Replacing Brake Rotors..............................................................................................................19209
Refinishing Brake Rotors............................................................................................................19209
Rear Drum (In Disc) Inside Diameter Check...........................................................................................19210
Rear Disc Brake Caliper Assembly........................................................................................................19211
Rear Disc Brake Caliper Assembly and Associated Parts...............................................................................19211
Removal.............................................................................................................................19211
Installation........................................................................................................................19212
Rear Disc Brake Caliper.................................................................................................................19214
Rear Disc Brake Caliper Disassembled View...........................................................................................19214
Disassembly.........................................................................................................................19214
Inspection and Repair...............................................................................................................19215
Reassembly..........................................................................................................................19215
Main Data and Specifications........................................................................................................19217
5D PARKING BRAKE SYSTEM.....................................................................................................................19218
Service Precaution......................................................................................................................19218
General Description.....................................................................................................................19218
Operation...............................................................................................................................19219
Parking Brake Lever and Front Cable.....................................................................................................19220
Parking Brake Lever, Front Cable and Associated Parts...............................................................................19220
Removal.............................................................................................................................19220
Installation........................................................................................................................19221
Parking Brake Rear Cable................................................................................................................19222
Parking Brake Rear Cable and Associated Parts.......................................................................................19222
Removal.............................................................................................................................19222
Installation........................................................................................................................19223
Inspection and Repair...............................................................................................................19224
Parking Brake Adjustment................................................................................................................19224
Main Data and Specifications............................................................................................................19225
Sec.6 ENGINE....................................................................................................................................19226
6A ENGINE MECHANICAL........................................................................................................................19226
Service Precaution......................................................................................................................19227
General Description.....................................................................................................................19228
Engine Diagnosis........................................................................................................................19229
Cylinder Head Cover LH..................................................................................................................19244
Removal.............................................................................................................................19244
Installation........................................................................................................................19245
Cylinder Head Cover RH..................................................................................................................19246
Removal.............................................................................................................................19246
Installation........................................................................................................................19246
Common Chamber..........................................................................................................................19247
Removal.............................................................................................................................19247
Installation........................................................................................................................19247
Exhaust Manifold LH.....................................................................................................................19249
Removal.............................................................................................................................19249
Installation........................................................................................................................19249
Exhaust Manifold RH.....................................................................................................................19250
Removal.............................................................................................................................19250
Installation........................................................................................................................19250
Crankshaft Pulley.......................................................................................................................19251
Removal.............................................................................................................................19251
Installation........................................................................................................................19251
Timing Belt.............................................................................................................................19252
Removal.............................................................................................................................19252
Installation........................................................................................................................19253
Camshaft................................................................................................................................19257
Removal.............................................................................................................................19257
Installation........................................................................................................................19257
Cylinder Head...........................................................................................................................19260
Removal.............................................................................................................................19260
Installation........................................................................................................................19260
Valve Stem Oil Controller , Valve Spring and Valve Guide................................................................................19262
Removal.............................................................................................................................19262
Installation........................................................................................................................19262
Piston, Piston Ring and Connecting Rod..................................................................................................19263
Removal.............................................................................................................................19263
Installation........................................................................................................................19264
Crankshaft and Main Bearings............................................................................................................19265
Removal.............................................................................................................................19265
Installation........................................................................................................................19266
Rear Oil Seal...........................................................................................................................19270
Removal.............................................................................................................................19270
Installation........................................................................................................................19270
Engine Assembly.........................................................................................................................19271
Removal.............................................................................................................................19271
Installation........................................................................................................................19272
Cylinder Head...........................................................................................................................19274
Cylinder Head and Associated Parts..................................................................................................19274
Disassembly.........................................................................................................................19275
Clean...............................................................................................................................19275
Inspection and Repair...............................................................................................................19275
Reassembly..........................................................................................................................19276
Valve Spring, Oil Controller, Valve, Valve Guide........................................................................................19278
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts...............................................................19278
Disassembly.........................................................................................................................19278
Inspection and Repair...............................................................................................................19279
Reassembly..........................................................................................................................19282
Valve Clearance Adjustments.............................................................................................................19283
Camshaft................................................................................................................................19285
Camshaft and Associated Parts.......................................................................................................19285
Disassembly.........................................................................................................................19285
Inspection and Repair...............................................................................................................19286
Reassembly..........................................................................................................................19288
Crankshaft..............................................................................................................................19291
Crankshaft and Associated Parts.....................................................................................................19291
Disassembly.........................................................................................................................19292
Inspection and Repair...............................................................................................................19292
Inspection and Repair...............................................................................................................19293
Reassembly..........................................................................................................................19295
Piston and Connecting Rod...............................................................................................................19299
Piston, Connecting Rod and Associate Parts..........................................................................................19299
Disassembly.........................................................................................................................19299
Inspection and Repair...............................................................................................................19300
Reassembly..........................................................................................................................19304
Cylinder Block..........................................................................................................................19306
Cylinder Block and Associated Parts.................................................................................................19306
Disassembly.........................................................................................................................19306
Inspection and Repair...............................................................................................................19307
Reassembly..........................................................................................................................19308
Main Data and Specification.............................................................................................................19311
Special Tool............................................................................................................................19317
6B ENGINE COOLING...........................................................................................................................19319
Service Precaution......................................................................................................................19319
General Description.....................................................................................................................19320
Diagnosis...............................................................................................................................19323
Draining and Refilling Cooling System...................................................................................................19324
Water Pump..............................................................................................................................19325
Water Pump and Associated Parts.....................................................................................................19325
Removal.............................................................................................................................19325
Inspection..........................................................................................................................19325
Installation........................................................................................................................19325
Thermostat..............................................................................................................................19326
Thermostat and Associated Parts.....................................................................................................19326
Removal.............................................................................................................................19326
Inspection..........................................................................................................................19326
Installation........................................................................................................................19326
Radiator................................................................................................................................19327
Radiator and Associated Parts.......................................................................................................19327
Removal.............................................................................................................................19327
Inspection..........................................................................................................................19328
Installation........................................................................................................................19329
Drive Belt and Cooling Fan..............................................................................................................19330
Drive Belt and Associated Parts.....................................................................................................19330
Inspection..........................................................................................................................19330
Installation........................................................................................................................19330
Main Data and Specifications............................................................................................................19331
Special Tool............................................................................................................................19332
6C ENGINE FUEL..............................................................................................................................19333
Service Precaution......................................................................................................................19333
General Description.....................................................................................................................19334
Fuel Metering...........................................................................................................................19335
Fuel Filter.............................................................................................................................19336
Fuel Filter and Associated Parts....................................................................................................19336
Removal.............................................................................................................................19336
Inspection..........................................................................................................................19336
Installation........................................................................................................................19336
Inspection..........................................................................................................................19337
In–Tank Fuel Filter.................................................................................................................19337
Fuel Pump Flow Test.................................................................................................................19337
Fuel Pump...............................................................................................................................19338
Fuel Pump and Associated Parts......................................................................................................19338
Removal.............................................................................................................................19338
Installation........................................................................................................................19338
Fuel Pump Relay.........................................................................................................................19338
General Description.....................................................................................................................19338
Fuel Tank...............................................................................................................................19339
Fuel Tank and Associated Parts......................................................................................................19339
Removal.............................................................................................................................19339
Installation........................................................................................................................19339
Fuel Tube / Quick – Connect Fittings....................................................................................................19340
Precautions.........................................................................................................................19340
Cautions During Work................................................................................................................19340
Removal.............................................................................................................................19340
Reuse of Quick–Connector................................................................................................................19341
Assembling Advice.......................................................................................................................19342
Fuel Gauge Unit.........................................................................................................................19343
Fuel Gauge Unit and Associated Parts................................................................................................19343
Removal.............................................................................................................................19343
Installation........................................................................................................................19343
Fuel Filler Cap.........................................................................................................................19344
General Description.....................................................................................................................19344
Inspection..........................................................................................................................19344
Main Data and Specifications............................................................................................................19345
6D1 ENGINE ELECTRICAL.......................................................................................................................19346
Battery.................................................................................................................................19346
General Description.................................................................................................................19346
Diagnosis...........................................................................................................................19346
Battery Charging....................................................................................................................19347
Jump Starting.......................................................................................................................19347
Battery Removal.....................................................................................................................19348
Battery Installation................................................................................................................19348
Main Data and Specifications........................................................................................................19349
6D2 IGNITION SYSTEM.........................................................................................................................19350
Service Precaution......................................................................................................................19350
General Description.....................................................................................................................19351
Diagnosis...............................................................................................................................19351
Ignition Coil...........................................................................................................................19352
Removal.............................................................................................................................19352
Inspection and Repair...............................................................................................................19352
Installation........................................................................................................................19352
Spark Plug..............................................................................................................................19354
Removal.............................................................................................................................19354
Inspection and Repair...............................................................................................................19354
Installation........................................................................................................................19354
Crankshaft Position Sensor..............................................................................................................19355
Removal.............................................................................................................................19355
Installation........................................................................................................................19355
Main Data and Specifications............................................................................................................19356
6D3 STARTING AND CHARGING SYSTEM............................................................................................................19357
Service Precaution......................................................................................................................19357
Starting System.........................................................................................................................19358
General Description.....................................................................................................................19358
Diagnosis...............................................................................................................................19360
Starter.................................................................................................................................19361
Removal.............................................................................................................................19361
Installation........................................................................................................................19361
Disassembled View...................................................................................................................19362
Disassembly.........................................................................................................................19363
Inspection and Repair...............................................................................................................19365
Reassembly..........................................................................................................................19369
Main Data and Specifications........................................................................................................19371
Charging System.........................................................................................................................19374
General Description.....................................................................................................................19374
General On–Vehicle Inspection...........................................................................................................19374
Generator...............................................................................................................................19375
Removal.............................................................................................................................19375
Inspection..........................................................................................................................19375
Installation........................................................................................................................19375
Disassembled View...................................................................................................................19376
Disassembly.........................................................................................................................19377
Inspection and Repair...............................................................................................................19379
Reassembly..........................................................................................................................19381
Bench Test..........................................................................................................................19381
Main Data and Specifications............................................................................................................19382
6E TROOPER 3.5L ENGINE DRIVEABILITY AND EMISSIONS...........................................................................................19383
Specifications..........................................................................................................................19388
Tightening Specifications...........................................................................................................19388
Diagrams and Schematics.................................................................................................................19389
PCM Wiring Diagram (1 of 8).........................................................................................................19389
PCM Wiring Diagram (2 of 8).........................................................................................................19390
PCM Wiring Diagram (3 of 8).........................................................................................................19391
PCM Wiring Diagram (4 of 8).........................................................................................................19392
PCM Wiring Diagram (5 of 8).........................................................................................................19393
PCM Wiring Diagram (6 of 8).........................................................................................................19394
PCM Wiring Diagram (7 of 8).........................................................................................................19395
PCM Wiring Diagram (8 of 8).........................................................................................................19396
PCM Pinouts.............................................................................................................................19397
PCM Pinout Table, 80-Way Blue Connector – Row “F1 ~ 20”.............................................................................19397
PCM Pinout Table, 80-Way Blue Connector – Row “F20 ~ 40”............................................................................19398
PCM Pinout Table, 80-Way Blue Connector – Row “F41 ~ 60”............................................................................19400
PCM Pinout Table, 80-Way Blue Connector – Row “F61 ~ 80”............................................................................19402
PCM Pinout Table, 80-Way Red Connector – Row “S1 ~ 20”..............................................................................19404
PCM Pinout Table, 80-Way Red Connector – Row “S21 ~ 40”.............................................................................19406
PCM Pinout Table, 80-Way Red Connector – Row “S41 ~ 60”.............................................................................19408
PCM Pinout Table, 80-Way Red Connector – Row “S61 ~ 80”.............................................................................19410
Component Locators..................................................................................................................19412
Undercarriage Component Locator.....................................................................................................19414
Fuse and Relay Panel (Underhood Electrical Center)..................................................................................19415
Sensors and Miscellaneous Component Locators........................................................................................19416
Diagnosis...............................................................................................................................19418
Strategy-Based Diagnostics..........................................................................................................19418
DTC Stored..........................................................................................................................19418
No DTC..............................................................................................................................19418
No Matching Symptom.................................................................................................................19418
Intermittents.......................................................................................................................19418
No Trouble Found....................................................................................................................19418
Verifying Vehicle Repair............................................................................................................19418
General Service Information.............................................................................................................19418
OBD II Serviceablity Issues.........................................................................................................19418
Visual / Physical Engine Compartment Inspection.....................................................................................19419
Basic Knowledge of Tools Required...................................................................................................19419
Serial Data Communications..............................................................................................................19420
Class 2 Serial Data Communications..................................................................................................19420
On-Board Diagnostic (OBD II)............................................................................................................19420
On-Board Diagnostic Tests...........................................................................................................19420
Comprehensive Component Monitor Diagnostic Operation................................................................................19420
System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...................................19421
Common OBD II Terms.................................................................................................................19421
The Diagnostic Executive............................................................................................................19421
DTC Types...........................................................................................................................19422
Decimal/Binary/Hexadecimal Conversions..............................................................................................19423
Verifying Vehicle Repair............................................................................................................19424
Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool.........................................................................19424
Tech 2..............................................................................................................................19425
Tech 2 Features.....................................................................................................................19426
Getting Started.....................................................................................................................19426
Operating Procedure (For Example)...................................................................................................19427
DTC Modes...........................................................................................................................19428
DTC Information Mode................................................................................................................19428
Miscellaneous Test..................................................................................................................19429
Lamps Test..........................................................................................................................19429
Relays Test.........................................................................................................................19431
EVAP Test...........................................................................................................................19432
Fuel System Test....................................................................................................................19433
Instruments Test....................................................................................................................19435
EGR Control Test....................................................................................................................19437
Variable Intake Manifold Solenoid Test..............................................................................................19437
Injector Balance Test...............................................................................................................19439
Plotting Snapshot Graph.................................................................................................................19439
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)......................................................19440
Flow Chart for Snapshot Replay (Plotting Graph).....................................................................................19441
Primary System-Based Diagnostic.........................................................................................................19442
Primary System-Based Diagnostic.....................................................................................................19442
Fuel Control Heated Oxygen Sensor...................................................................................................19442
HO2S Heater.........................................................................................................................19442
Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation.....................................................................19442
Misfire Monitor Diagnostic Operation....................................................................................................19443
Misfire Monitor Diagnostic Operation................................................................................................19443
Misfire Counters....................................................................................................................19443
Fuel Trim System Monitor Diagnostic Operation...........................................................................................19444
Fuel Trim System Monitor Diagnostic Operation.......................................................................................19444
Fuel Trim Cell Diagnostic Weights...................................................................................................19444
On-Board Diagnostic (OBD II) System Check...............................................................................................19445
Circuit Description.................................................................................................................19445
Diagnostic Aids.....................................................................................................................19445
Test Description....................................................................................................................19445
A/C Clutch Control Circuit Diagnosis....................................................................................................19448
Circuit Description.................................................................................................................19448
Diagnostic Aids.....................................................................................................................19448
A/C Clutch Diagnosis................................................................................................................19449
Electronic Ignition System Diagnosis....................................................................................................19453
EVAP Canister Purge Solenoid and EVAP Vent Solenoid Valve...............................................................................19453
Visual Check of The Evaporative Emission Canister.......................................................................................19453
Fuel Metering System Check..............................................................................................................19453
Fuel System Pressure Test...............................................................................................................19453
Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure..............................................................19453
Test Description....................................................................................................................19453
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)...........................................19454
Powertrain Control Module (PCM) Diagnosis...............................................................................................19458
Multiple PCM Information Sensor DTCs Set................................................................................................19458
Circuit Description.................................................................................................................19458
Diagnostic Aids.....................................................................................................................19458
Exhaust Gas Recirculation (EGR) Diagnosis...............................................................................................19461
Engine Tech 2 Data Definitions and Ranges...............................................................................................19461
Typical Scan Data Values................................................................................................................19463
Test Conditions.....................................................................................................................19463
No Malfunction Indicator Lamp (MIL).....................................................................................................19469
Circuit Description.................................................................................................................19469
Diagnostic Aids.....................................................................................................................19469
Malfunction Indicator Lamp (MIL) “ON” Steady............................................................................................19472
Circuit description.................................................................................................................19472
Diagnostic Aids.....................................................................................................................19472
No Reduced Power Lamp (RPL).............................................................................................................19474
Circuit Description.................................................................................................................19474
Diagnostic Aids.....................................................................................................................19474
Reduced Power Lamp (RPL) “ON” Steady....................................................................................................19477
Circuit description.................................................................................................................19477
Diagnostic Aids.....................................................................................................................19477
Engine Cranks But Will Not Run..........................................................................................................19479
Circuit Description.................................................................................................................19481
Diagnostic Aids.....................................................................................................................19481
Test Description....................................................................................................................19481
Fuel System Electrical Test.............................................................................................................19486
Circuit Description.................................................................................................................19487
Diagnostic Aids.....................................................................................................................19487
Test Description....................................................................................................................19487
Fuel Pressure Relief Procedure......................................................................................................19487
Electric Throttle Control (ETC) System Check............................................................................................19490
Circuit Description.................................................................................................................19491
Diagnostic Aids.....................................................................................................................19491
Test Description....................................................................................................................19491
Fuel System Diagnosis...................................................................................................................19494
Circuit Description.................................................................................................................19495
Test Description....................................................................................................................19495
Fuel Pressure Relief Procedure......................................................................................................19496
Exhaust Gas Recirculation (EGR) System Check............................................................................................19499
Circuit Description.................................................................................................................19499
Manifold Absolute Pressure (MAP) Output Check...........................................................................................19501
Circuit Description.................................................................................................................19501
Evaporative (EVAP) Emissions Canister Purge Valve Check.................................................................................19503
Circuit Description.................................................................................................................19503
Diagnostic Aids.....................................................................................................................19503
PCM Diagnostic Trouble Codes............................................................................................................19506
DTC P0101 MAF System Performance........................................................................................................19510
DTC P0102 MAF Sensor Circuit Low Frequency..............................................................................................19513
DTC P0103 MAF Sensor Circuit High Frequency.............................................................................................19516
DTC P0106 MAP System Performance........................................................................................................19518
DTC P0107 MAP Sensor Circuit Low Voltage................................................................................................19521
DTC P0108 MAP Sensor Circuit High Voltage...............................................................................................19524
DTC P0112 IAT Sensor Circuit Low Voltage................................................................................................19527
DTC P0113 IAT Sensor Circuit High Voltage...............................................................................................19530
DTC P0117 ECT Sensor Circuit Low Voltage................................................................................................19533
DTC P0118 ECT Sensor Circuit High Voltage...............................................................................................19536
DTC P0125 ECT Excessive Time to Closed Loop Fuel Control................................................................................19539
DTC P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1......................................................................................19542
DTC P0132 HO2S Circuit High Voltage Bank 1 Sensor 1.....................................................................................19545
DTC P0133 HO2S Slow Response Bank 1 Sensor 1............................................................................................19548
DTC P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1............................................................................19552
DTC P0135 HO2S Heater Circuit Bank 1 Sensor 1...........................................................................................19555
DTC P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2......................................................................................19558
DTC P0138 HO2S Circuit High Voltage Bank 1 Sensor 2.....................................................................................19561
DTC P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2............................................................................19564
DTC P0141 HO2S Heater Circuit Bank 1 Sensor 2...........................................................................................19567
DTC P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1......................................................................................19570
DTC P0152 HO2S Circuit High Voltage Bank 2 Sensor 1.....................................................................................19573
DTC P0153 HO2S Slow Response Bank 2 Sensor 1............................................................................................19576
DTC P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1............................................................................19580
DTC P0155 HO2S Heater Circuit Open Bank 2 Sensor 1......................................................................................19583
DTC P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2......................................................................................19586
DTC P0158 HO2S Circuit High Voltage Bank 2 Sensor 2.....................................................................................19589
DTC P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2............................................................................19592
DTC P0161 HO2S Heater Circuit Bank 2 Sensor 2...........................................................................................19595
DTC P0171 Fuel Trim System Lean Bank 1..................................................................................................19598
DTC P0172 Fuel Trim System Rich Bank 1..................................................................................................19602
DTC P0174 Fuel Trim System Lean Bank 2..................................................................................................19606
DTC P0175 Fuel Trim System Rich Bank 2..................................................................................................19610
DTC P0201 Injector 1 Control Circuit....................................................................................................19614
DTC P0202 Injector 2 Control Circuit....................................................................................................19617
DTC P0203 Injector 3 Control Circuit....................................................................................................19620
DTC P0204 Injector 4 Control Circuit....................................................................................................19623
DTC P0205 Injector 5 Control Circuit....................................................................................................19626
DTC P0206 Injector 6 Control Circuit....................................................................................................19629
DTC P0300 Engine Misfire Detected.......................................................................................................19632
DTC P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault..................................................................19636
DTC P0336 58X Reference Signal Circuit..................................................................................................19639
DTC P0337 CKP Sensor Circuit Low Frequency..............................................................................................19642
DTC P0351 Ignition 1 Control Circuit....................................................................................................19645
DTC P0352 Ignition 2 Control Circuit....................................................................................................19648
DTC P0353 Ignition 3 Control Circuit....................................................................................................19651
DTC P0354 Ignition 4 Control Circuit....................................................................................................19654
DTC P0355 Ignition 5 Control Circuit....................................................................................................19657
DTC P0356 Ignition 6 Control Circuit....................................................................................................19660
DTC P0401 EGR Flow Insufficient.........................................................................................................19663
DTC P0402 EGR Pintle Crank Error........................................................................................................19666
DTC P0404 EGR Open Stuck................................................................................................................19668
DTC P0405 EGR Low Voltage...............................................................................................................19670
DTC P0406 EGR High Voltage..............................................................................................................19673
DTC P0420 TWC System Low Efficiency Bank 1..............................................................................................19676
DTC P0430 TWC System Low Efficiency Bank 2..............................................................................................19679
DTC P0440 EVAP System...................................................................................................................19682
DTC P0442 EVAP System Small Leak Detected...............................................................................................19685
DTC P0444 EVAP Purge Control Circuit Open...............................................................................................19688
DTC P0445 EVAP Purge Control Circuit Short..............................................................................................19690
DTC P0446 EVAP Canister Vent Control Malfunction........................................................................................19692
DTC P0447 EVAP Vent Solenoid Circuit Open...............................................................................................19695
DTC P0448 EVAP Vent solenoid Circuit Short..............................................................................................19697
DTC P0452 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) Low Voltage.................................................................19699
DTC P0453 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) High Voltage................................................................19702
DTC P0456 EVAP Very Small Leak..........................................................................................................19705
DTC P0461 Fuel Level Sensor Performance.................................................................................................19708
DTC P0462 Fuel Level Sensor Circuit‐Low Voltage.........................................................................................19710
DTC P0463 Fuel Level Sensor Circuit‐High Voltage........................................................................................19713
DTC P0464 Fuel Level Sensor Noisy Signal................................................................................................19715
DTC P0502 VSS Circuit Low Input.........................................................................................................19717
DTC P0506 Idle Air Control System Low RPM...............................................................................................19720
DTC P0507 Idle Air Control System High RPM..............................................................................................19723
DTC P0562 System Voltage Low............................................................................................................19726
DTC P0563 System Voltage High...........................................................................................................19728
DTC P0565 Cruise Main Switch Circuit Error..............................................................................................19730
DTC P0566 Cruise Cancel Switch Circuit Error............................................................................................19732
DTC P0567 Cruise Resume Switch Circuit Error............................................................................................19734
DTC P0568 Cruise Set Switch Circuit Error...............................................................................................19736
DTC P0571 No Brake Switch Signal........................................................................................................19738
DTC P0601 PCM Memory....................................................................................................................19740
DTC P0602 PCM Programming Error.........................................................................................................19742
DTC P0604 PCM RAM Error.................................................................................................................19744
DTC P0606 PCM Internal Performance......................................................................................................19746
DTC P0660 VIM Solenoid Circuit Open.....................................................................................................19748
DTC P0662 VIM Solenoid Circuit Short....................................................................................................19750
DTC P1106 MAP Sensor Circuit Intermittent High Voltage..................................................................................19752
DTC P1107 MAP Circuit Intermittent Low Voltage..........................................................................................19754
DTC P1111 IAT Sensor Circuit Intermittent High Voltage..................................................................................19756
DTC P1112 IAT Sensor Circuit Intermittent Low Voltage...................................................................................19759
DTC P1114 ECT Sensor Circuit Intermittent Low Voltage...................................................................................19761
DTC P1115 ECT Sensor Circuit Intermittent High Voltage..................................................................................19763
DTC P1120-TPS 1 Throttle Position Sensor (TPS1) Circuit Fault...........................................................................19766
DTC P1125 ETC (Electric throttle control) Limit Performance Mode........................................................................19769
DTC P1133 HO2S Insufficient Switching Bank 1 Sensor 1...................................................................................19772
DTC P1134 HO2S Transition Time Ratio Bank 1 Sensor 1....................................................................................19776
DTC P1153 HO2S Insufficient Switching Bank 2 Sensor 1...................................................................................19780
DTC P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1............................................................................19784
DTC P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1)...........................................................................19788
DTC P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2)...........................................................................19790
DTC P1171 Fuel System Lean During Acceleration..........................................................................................19792
DTC P1220 Throttle Position Senser2 (TPS2) Circuit Fault................................................................................19795
DTC P1221 TPS1 ‐ TPS2 correlation(Circuit Performance)..................................................................................19798
DTC P1271 APS 1‐ 2 Correlation Error....................................................................................................19801
DTC P1272 APS 2 ‐ 3 Correlation Error...................................................................................................19804
DTC P1273 APS 1 ‐ 3 Correlation Error...................................................................................................19807
DTC P1275 APS 1 Circuit Fault...........................................................................................................19810
DTC P1280 APS 2 Circuit Fault...........................................................................................................19812
DTC P1285 APS 3 Circuit Fault...........................................................................................................19814
DTC P1290 ETC Forced Idle Mode..........................................................................................................19816
DTC P1295 Power Management Mode.........................................................................................................19818
DTC P1299 ETC Forced Engine Shutdown Mode...............................................................................................19820
DTC P1310 ION Sensing Module Diagnosis..................................................................................................19822
DTC P1311 ION Sensing Module SEC Line 1 Circuit Fault...................................................................................19825
DTC P1312 ION Sensing Module SEC Line 2 Circuit Fault...................................................................................19828
DTC P1326 ION Sensing Module Combustion Quality Input Circuit Fault.....................................................................19831
DTC P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)..........................................................19834
DTC P1404 EGR Stuck Closed..............................................................................................................19837
DTC P1441 EVAP System Flow During Non-Purge.............................................................................................19840
DTC P1514 TPS - MAF Correlation Error...................................................................................................19843
DTC P1515 Command - Actual TPS Correlation Error........................................................................................19847
DTC P1516 Command - Actual TPS Correlation Error........................................................................................19850
DTC P1523 Actuator Control Return Performance...........................................................................................19853
DTC P1574 Brake Switch No Operation.....................................................................................................19856
DTC P1635 Reference Voltage # 1 Circuit Fault...........................................................................................19858
DTC P1636 PCM RAM Stack.................................................................................................................19860
DTC P1639 Reference Voltage # 2 Circuit Fault...........................................................................................19861
DTC P1640 Driver-1-Output Circuit Fault (ODM)...........................................................................................19863
DTC P1650 Quad Driver Module “A” Fault..................................................................................................19865
Symptom Diagnosis.......................................................................................................................19868
Default Matrix Table....................................................................................................................19897
On Vehicle Service Crankshaft Position (CKP) Sensor.....................................................................................19900
Engine Coolant Temperature (ECT) Sensor.................................................................................................19900
Heated Oxygen Sensor (HO2S).............................................................................................................19901
Intake Air Temperature (IAT) Sensor.....................................................................................................19904
ION Sensing Module......................................................................................................................19904
Mass Air Flow (MAF) Sensor..............................................................................................................19905
Manifold Absolute Pressure (MAP) Sensor.................................................................................................19906
Malfunction Indicator Lamp (MIL)........................................................................................................19907
Reduced Power Lamp......................................................................................................................19907
Powertrain Control Module (PCM).........................................................................................................19907
Service Precaution..................................................................................................................19907
Removal Procedure...................................................................................................................19907
Installation Procedure..............................................................................................................19908
EEPROM..................................................................................................................................19909
Throttle Position (TP) Sensor...........................................................................................................19909
Vehicle Speed Sensor (VSS)..............................................................................................................19910
Air Cleaner/Air Filter..................................................................................................................19911
Common Chamber..........................................................................................................................19911
Accelerator Pedal Replacement...........................................................................................................19912
Accelerator Position Sensor Replacement.................................................................................................19913
Accelerator Position Sensor Adjustment..................................................................................................19913
Fuel Filler Cap.........................................................................................................................19914
Fuel Filter.............................................................................................................................19914
Fuel Gauge Unit.........................................................................................................................19916
Fuel Injectors..........................................................................................................................19916
Fuel Metering System....................................................................................................................19917
Fuel Pump Assembly......................................................................................................................19918
Fuel Pump Relay.........................................................................................................................19918
Fuel Rail Assembly......................................................................................................................19919
Fuel Tank...............................................................................................................................19920
Throttle Body (TB)......................................................................................................................19920
Electronic Ignition System..............................................................................................................19922
Catalytic Converter.....................................................................................................................19923
Air Conditioning Thermo Relay...........................................................................................................19923
EVAP Canister Hoses.....................................................................................................................19923
EVAP Canister...........................................................................................................................19924
EVAP Canister Vent Solenoid.............................................................................................................19925
Fuel Tank Pressure (Vapor Pressure) Sensor..............................................................................................19926
EVAP Canister Purge Solenoid (Purge Duty Solenoid Valve)................................................................................19927
Fuel Tank Vent Valve (Vent Solenoid Valve)..............................................................................................19927
Linear Exhaust Gas Recirculation (EGR) Valve............................................................................................19927
Positive Crankcase Ventilation (PCV) Valve..............................................................................................19928
Wiring and Connectors...................................................................................................................19929
PCM Connectors and Terminals............................................................................................................19930
Wire Harness Repair: Twisted Shielded Cable.............................................................................................19930
Twisted Leads...........................................................................................................................19931
Weather-Pack Connector..................................................................................................................19932
Com-Pack III............................................................................................................................19933
Metri-Pack..............................................................................................................................19934
General Description (PCM and Sensors)...................................................................................................19935
58X Reference PCM Input.............................................................................................................19935
A/C Request Signal..................................................................................................................19935
Crankshaft Position (CKP) Sensor....................................................................................................19935
Engine Coolant Temperature (ECT) Sensor.............................................................................................19935
Electrically Erasable Programmable Read Only Memory (EEPROM)........................................................................19935
Fuel Control Heated Oxygen Sensors..................................................................................................19935
Catalyst Monitor Heated Oxygen Sensors..............................................................................................19936
Intake Air Temperature (IAT) Sensor.................................................................................................19936
Linear Exhaust Gas Recirculation (EGR) Control......................................................................................19937
Mass Air Flow (MAF) Sensor..........................................................................................................19937
Manifold Absolute Pressure (MAP) Sensor.............................................................................................19937
Powertrain Control Module (PCM).....................................................................................................19938
PCM Function........................................................................................................................19938
PCM Components......................................................................................................................19938
PCM Voltage Description.............................................................................................................19938
PCM Input/Outputs...................................................................................................................19938
PCM Service Precautions.............................................................................................................19939
Reprogramming The PCM...............................................................................................................19939
Throttle Position (TP) Sensor.......................................................................................................19939
Transmission Fluid Temperature (TFT) Sensor.........................................................................................19939
Transmission Range Switch (Mode Switch).............................................................................................19939
Vehicle Speed Sensor (VSS)..........................................................................................................19939
Use of Circuit Testing Tools........................................................................................................19939
Aftermarket Electrical and Vacuum Equipment.........................................................................................19940
Electrostatic Discharge Damage......................................................................................................19940
General Description (Air Induction).....................................................................................................19940
Air Induction System................................................................................................................19940
General Description (Fuel Metering).....................................................................................................19941
Acceleration Mode...................................................................................................................19941
Battery Voltage Correction Mode.....................................................................................................19941
Clear Flood Mode....................................................................................................................19941
Deceleration Mode...................................................................................................................19941
Engine Speed/Vehicle Speed/Fuel Disable Mode........................................................................................19941
Fuel Cutoff Mode....................................................................................................................19941
Fuel Injector.......................................................................................................................19941
Fuel Metering System Components.....................................................................................................19941
Fuel Metering System Purpose........................................................................................................19941
Fuel Pressure Regulator.............................................................................................................19942
Fuel Pump Electrical Circuit........................................................................................................19942
Fuel Rail...........................................................................................................................19942
Run Mode............................................................................................................................19942
Starting Mode.......................................................................................................................19942
Throttle Body Unit..................................................................................................................19943
General Description (Electronic Ignition System)........................................................................................19943
Crankshaft Position (CKP) Sensor....................................................................................................19943
Electronic Ignition.................................................................................................................19943
Ignition Coils......................................................................................................................19943
Ignition Control....................................................................................................................19943
Ignition Control PCM Output.........................................................................................................19944
Powertrain Control Module (PCM).....................................................................................................19944
Spark Plug..........................................................................................................................19945
A/C Clutch Diagnosis....................................................................................................................19946
A/C Clutch Circuit Operation........................................................................................................19946
A/C Clutch Circuit Purpose..........................................................................................................19946
A/C Request Signal..................................................................................................................19946
General Description (Evaporative (EVAP) Emission System)................................................................................19947
EVAP Emission Control System Purpose................................................................................................19947
EVAP Emission Control System Operation..............................................................................................19947
Enhanced Evaporative Emission Control System........................................................................................19947
General Description (Exhaust Gas Recirculation (EGR) System)............................................................................19950
EGR Purpose.........................................................................................................................19950
Linear EGR Valve....................................................................................................................19951
Linear EGR Control..................................................................................................................19951
Linear EGR Valve Operation and Results of Incorrect Operation.......................................................................19951
EGR Pintle Position Sensor..........................................................................................................19951
General Description (Positive Crankcase Ventilation (PCV) System).......................................................................19951
Crankcase Ventilation System Purpose................................................................................................19951
Crankcase Ventilation System Operation..............................................................................................19951
Special Tools...........................................................................................................................19953
6F ENGINE EXHAUST...........................................................................................................................19955
General Description.....................................................................................................................19956
Front Exhaust Pipe......................................................................................................................19957
Front Exhaust Pipe and Associated Parts.............................................................................................19957
Removal.............................................................................................................................19957
Installation........................................................................................................................19957
Three Way Catalytic Converter LH........................................................................................................19958
Removal.............................................................................................................................19958
Installation........................................................................................................................19958
Three Way Catalytic Converter RH........................................................................................................19959
Removal.............................................................................................................................19959
Installation........................................................................................................................19959
Exhaust Silencer........................................................................................................................19960
Exhaust Silencer and Associated Parts...............................................................................................19960
Removal.............................................................................................................................19960
Installation........................................................................................................................19960
Rear Exhaust pipe.......................................................................................................................19961
Rear Exhaust pipe and Associated Parts..............................................................................................19961
Removal.............................................................................................................................19961
Installation........................................................................................................................19961
Main Data and Specifications............................................................................................................19962
6G ENGINE LUBRICATION.......................................................................................................................19963
Service Precaution......................................................................................................................19963
General Description.....................................................................................................................19964
Oil Pump................................................................................................................................19965
Oil Pump and Associated Parts.......................................................................................................19965
Disassembly.........................................................................................................................19965
Inspection and Repair...............................................................................................................19966
Reassembly..........................................................................................................................19967
Oil Pan and Crankcase...................................................................................................................19969
Removal.............................................................................................................................19969
Installation........................................................................................................................19969
Oil Pump................................................................................................................................19972
Removal.............................................................................................................................19972
Installation........................................................................................................................19972
Oil Pump Oil Seal.......................................................................................................................19974
Removal.............................................................................................................................19974
Installation........................................................................................................................19974
Oil Filter..............................................................................................................................19975
Removal.............................................................................................................................19975
Installation........................................................................................................................19975
Main Data and Specification.............................................................................................................19976
6H ENGINE SPEED CONTROL SYSTEM..............................................................................................................19977
Service Precaution......................................................................................................................19977
Accelerator Pedal.......................................................................................................................19978
Accelerator Pedal and Associated Parts..............................................................................................19978
Removal.............................................................................................................................19978
Installation........................................................................................................................19978
6J INDUCTION................................................................................................................................19979
Service Precaution......................................................................................................................19979
Air Cleaner Element.....................................................................................................................19980
Removal.............................................................................................................................19980
Inspection..........................................................................................................................19980
Installation........................................................................................................................19980
Sec.7 TRANSMISSION..............................................................................................................................19981
7A AUTOMATIC TRANSMISSION (4L30‐E)..........................................................................................................19981
Service Precaution......................................................................................................................19983
Construction............................................................................................................................19983
Range Reference Chart...................................................................................................................19984
Normal Operation Of 2000 4L30‐E Transmission............................................................................................19985
Diagnosis...............................................................................................................................19985
Driver Information......................................................................................................................19985
General Diagnosis Procedure.............................................................................................................19988
Preliminary Inspection Chart............................................................................................................19989
Checking Transmission Fluid Level and Condition.........................................................................................19990
Test Driving............................................................................................................................19991
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................19992
Mechanical / Hydraulic Diagnosis Symptoms Index.........................................................................................19993
Stall Test..............................................................................................................................20003
Line Pressure Test......................................................................................................................20003
Shift Speed Chart.......................................................................................................................20004
Lockup Speed Chart......................................................................................................................20006
Changing Transmission Fluid.............................................................................................................20007
Selector Lever..........................................................................................................................20007
Inspection..........................................................................................................................20007
Removal.............................................................................................................................20007
Installation........................................................................................................................20008
Mode Switch.............................................................................................................................20009
Removal.............................................................................................................................20009
Installation........................................................................................................................20009
Transmission (With Transfer Case / Extension Assembly)..................................................................................20011
Transmission And Associated Parts...................................................................................................20011
Removal.............................................................................................................................20012
Installation........................................................................................................................20013
Solenoid (Main Case Valve Body).........................................................................................................20018
Removal.............................................................................................................................20018
Installation........................................................................................................................20018
Solenoid (Adapter Case Valve Body)......................................................................................................20019
Removal.............................................................................................................................20019
Installation........................................................................................................................20019
Valve Body Assembly (Main Case).........................................................................................................20020
Removal.............................................................................................................................20020
Installation........................................................................................................................20020
Valve Body Assembly (Adapter Case)......................................................................................................20021
Removal.............................................................................................................................20021
Installation........................................................................................................................20021
Powertrain Control Module (PCM).........................................................................................................20021
Removal.............................................................................................................................20021
Installation........................................................................................................................20021
Speed Sensor (Extension Housing)........................................................................................................20022
Removal.............................................................................................................................20022
Installation........................................................................................................................20022
Transmission Oil Temperature Sensor (Main Case).........................................................................................20022
Removal.............................................................................................................................20022
Installation........................................................................................................................20022
Front Oil Seal (Converter Housing)......................................................................................................20023
Removal.............................................................................................................................20023
Installation........................................................................................................................20023
Rear Oil Seal (Extension Housing).......................................................................................................20023
Removal.............................................................................................................................20023
Installation........................................................................................................................20024
Transmission (4L30–E)...................................................................................................................20024
Disassembly.........................................................................................................................20024
Reassembly..........................................................................................................................20028
Converter Housing And Oil Pump Assembly.................................................................................................20038
Disassembled View...................................................................................................................20038
Disassembly.........................................................................................................................20038
Inspection And Repair...............................................................................................................20038
Reassembly..........................................................................................................................20038
Oil Pump................................................................................................................................20039
Disassembled View...................................................................................................................20039
Disassembly.........................................................................................................................20039
Inspection And Repair...............................................................................................................20040
Reassembly..........................................................................................................................20040
Main Case Valve Body....................................................................................................................20041
Disassembled View...................................................................................................................20041
Disassembly.........................................................................................................................20041
Inspection And Repair...............................................................................................................20042
Reassembly..........................................................................................................................20042
Adapter Case Valve Body.................................................................................................................20043
Disassembled View...................................................................................................................20043
Disassembly.........................................................................................................................20043
Inspection And Repair...............................................................................................................20043
Reassembly..........................................................................................................................20043
Third Clutch And Sprag Unit.............................................................................................................20045
Disassembled View...................................................................................................................20045
Disassembly.........................................................................................................................20045
Inspection And Repair...............................................................................................................20045
Reassembly..........................................................................................................................20046
Third Clutch............................................................................................................................20047
Disassembled View...................................................................................................................20047
Disassemble.........................................................................................................................20047
Inspection And Repair...............................................................................................................20047
Reassembly..........................................................................................................................20047
Sprag Unit..............................................................................................................................20049
Disassembled View...................................................................................................................20049
Disassembly.........................................................................................................................20049
Inspection And Repair...............................................................................................................20049
Reassembly..........................................................................................................................20049
Second Clutch...........................................................................................................................20050
Disassembled View...................................................................................................................20050
Disassembly.........................................................................................................................20050
Inspection And Repair...............................................................................................................20051
Reassembly..........................................................................................................................20051
3–4 Accumulator Piston..................................................................................................................20052
Disassembled View...................................................................................................................20052
Disassembly.........................................................................................................................20052
Inspection And Repair...............................................................................................................20053
Reassembly..........................................................................................................................20053
Reverse Clutch Piston And Center Support................................................................................................20054
Disassembled View...................................................................................................................20054
Disassembly.........................................................................................................................20054
Inspection And Repair...............................................................................................................20055
Reassembly..........................................................................................................................20055
Overrun Clutch And Turbine Shaft........................................................................................................20056
Disassembled View...................................................................................................................20056
Disassembly.........................................................................................................................20057
Inspection And Repair...............................................................................................................20057
Reassembly..........................................................................................................................20057
Main Data And Specification.............................................................................................................20059
Special Tools...........................................................................................................................20063
4L30–E Parts List.......................................................................................................................20066
Extension Housing Assembly Oil Seal.....................................................................................................20074
Extension Housing Assembly Rear Oil Seal and Associated Parts.......................................................................20074
Removal.............................................................................................................................20074
Installation........................................................................................................................20074
Extension Housing Assembly..............................................................................................................20076
Extension Housing Assembly and Associated Parts.....................................................................................20076
Removal.............................................................................................................................20077
Installation........................................................................................................................20077
Extension Housing Assembly..............................................................................................................20079
Extension Housing Assembly and Associated Parts.....................................................................................20079
Removal.............................................................................................................................20080
Installation........................................................................................................................20080
Extension Housing Assembly..........................................................................................................20082
Disassembly.........................................................................................................................20083
Reassembly..........................................................................................................................20083
Inspection and Repair...............................................................................................................20084
Main Data and Specifications............................................................................................................20085
Special Tools...........................................................................................................................20086
7A1 TRANSMISSION CONTROL SYSTEM (4L30‐E)....................................................................................................20087
Service Precaution......................................................................................................................20088
General Description.....................................................................................................................20088
Electronic Control Diagram..........................................................................................................20089
Powertrain Control Module (PCM).....................................................................................................20090
Control System Diagram..............................................................................................................20091
Shift Control.......................................................................................................................20092
Band Apply Control..................................................................................................................20092
Torque Converter Clutch Control (Electronically Controlled Capacity Clutch = ECCC)..................................................20092
Line Pressure Control...............................................................................................................20092
On–Board Diagnostic System..........................................................................................................20092
Fail Safe Mechanism.................................................................................................................20092
Torque Management Control...........................................................................................................20092
ATF Warning Control.................................................................................................................20092
ABS Control.........................................................................................................................20092
Reverse Lock Out Control............................................................................................................20092
Downhill Control....................................................................................................................20092
Uphill Control......................................................................................................................20092
Shift Mode Control..................................................................................................................20093
Gear Shift Control..................................................................................................................20094
Winter Drive Mode...................................................................................................................20095
Backup Mode.........................................................................................................................20095
Functions of Input / Output Components..............................................................................................20096
Diagnosis...............................................................................................................................20097
Electronic Diagnosis................................................................................................................20097
Check Trans Indicator...............................................................................................................20097
Diagnostic Check....................................................................................................................20097
“Check Trans” Check.................................................................................................................20098
Tech 2 OBD II Connection............................................................................................................20099
Transmission Data...................................................................................................................20104
OBD II Diagnostic Management System.................................................................................................20105
16 – Terminal Data Link Connector (DLC).............................................................................................20106
Malfunction Indicator Lamp (MIL)....................................................................................................20107
Types Of Diagnostic Trouble Codes (DTCs)............................................................................................20107
Clear DTC...........................................................................................................................20107
DTC Check...........................................................................................................................20108
PCM Precaution......................................................................................................................20108
Information On PCM..................................................................................................................20108
Intermittent Conditions.............................................................................................................20108
Transmission And PCM Identification.................................................................................................20109
Isuzu Trooper.......................................................................................................................20109
Diagnostic Trouble Code (DTC) Identification........................................................................................20110
DTC P0218 Transmission Fluid Over Temperature...........................................................................................20111
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position......................................................................20113
DTC P0706 Transmission Range Switch (Mode Switch) Performance...........................................................................20116
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance.......................................................................20119
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input.................................................................20122
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................20125
DTC P0719 Brake Switch Circuit Low (Stuck On)...........................................................................................20128
DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input....................................................................20131
DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent.................................................................20134
DTC P0724 Brake Switch Circuit High (Stuck Off).........................................................................................20137
DTC P0730 Gear Error Without Input Speed................................................................................................20139
DTC P0742 Torque Converter Clutch (TCC) System Stuck On.................................................................................20142
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical..............................................................20144
DTC P0751 Shift Solenoid A Performance (Stuck OFF)......................................................................................20146
DTC P0752 Shift Solenoid A Performance (Stuck ON).......................................................................................20148
DTC P0753 Shift Solenoid A Electrical...................................................................................................20150
DTC P0756 Shift Solenoid B Performance (Stuck OFF)......................................................................................20153
DTC P0757 Shift Solenoid B Performance (Stuck ON).......................................................................................20155
DTC P0758 Shift Solenoid B Electrical...................................................................................................20157
DTC P1850 Brake Band Apply Solenoid Malfunction.........................................................................................20161
DTC P1860 TCC PWM Solenoid Electrical...................................................................................................20165
DTC P1870 Transmission Component Slipping (TCC Stuck OFF)...............................................................................20168
Connector List..........................................................................................................................20170
7B MANUAL TRANSMISSION......................................................................................................................20172
Service Precaution......................................................................................................................20172
General Description.....................................................................................................................20173
Diagnosis...............................................................................................................................20174
Manual Transmission Assembly............................................................................................................20175
Removal.............................................................................................................................20175
Installation........................................................................................................................20179
Disassembled View...................................................................................................................20184
Disassembly.........................................................................................................................20187
Inspection..........................................................................................................................20205
Reassembly..........................................................................................................................20207
Main Data and Specifications............................................................................................................20233
Special Tools...........................................................................................................................20235
7C CLUTCH...................................................................................................................................20237
Service Precaution......................................................................................................................20237
General Description.....................................................................................................................20238
Diagnosis...............................................................................................................................20242
Clutch Assembly.........................................................................................................................20243
Clutch Assembly and Associated Parts................................................................................................20243
Removal.............................................................................................................................20243
Inspection and Repair...............................................................................................................20244
Installation........................................................................................................................20248
Clutch Control..........................................................................................................................20251
Clutch Control Parts................................................................................................................20251
Removal.............................................................................................................................20251
Inspection and Repair...............................................................................................................20251
Installation........................................................................................................................20252
Adjustment..........................................................................................................................20252
Master Cylinder.........................................................................................................................20255
Inspection and Repair...............................................................................................................20255
Slave Cylinder..........................................................................................................................20256
Disassembled View...................................................................................................................20256
Disassembly.........................................................................................................................20256
Inspection and Repair...............................................................................................................20256
Reassembly..........................................................................................................................20257
Main Data and Specifications............................................................................................................20258
Special Tools...........................................................................................................................20260
Sec.8 BODY AND ACCESSORIES......................................................................................................................20261
8A LIGHTING SYSTEM..........................................................................................................................20261
Service Precaution......................................................................................................................20262
Headlight Bulb..........................................................................................................................20262
Removal.............................................................................................................................20262
Installation........................................................................................................................20262
Headlight...............................................................................................................................20263
Headlight and Associated Parts......................................................................................................20263
Removal.............................................................................................................................20263
Installation........................................................................................................................20263
Headlight Adjustment................................................................................................................20263
Fog Light Bulb..........................................................................................................................20264
Removal.............................................................................................................................20264
Installation........................................................................................................................20264
Fog Light Assembly......................................................................................................................20265
Removal.............................................................................................................................20265
Installation........................................................................................................................20265
Fog Light Adjustment................................................................................................................20265
Front Side Marker Light Bulb............................................................................................................20265
Removal.............................................................................................................................20265
Installation........................................................................................................................20265
Parking Light Bulb......................................................................................................................20266
Removal and Installation............................................................................................................20266
Taillight Bulb..........................................................................................................................20266
Removal.............................................................................................................................20266
Installation........................................................................................................................20266
License Plate Light Bulb................................................................................................................20267
Removal.............................................................................................................................20267
Installation........................................................................................................................20267
Stoplight Bulb..........................................................................................................................20267
Removal and Installation............................................................................................................20267
High Mount Stoplight....................................................................................................................20268
Removal.............................................................................................................................20268
Installation........................................................................................................................20268
Front Turn Signal Light Bulb............................................................................................................20268
Removal.............................................................................................................................20268
Installation........................................................................................................................20268
Rear Turn Signal Light Bulb.............................................................................................................20269
Removal.............................................................................................................................20269
Installation........................................................................................................................20269
Cornering Light Bulb....................................................................................................................20269
Removal.............................................................................................................................20269
Installation........................................................................................................................20269
Backup Light Bulb.......................................................................................................................20270
Removal.............................................................................................................................20270
Installation........................................................................................................................20270
Dome Light Bulb.........................................................................................................................20270
Removal.............................................................................................................................20270
Installation........................................................................................................................20270
Luggage Room Light Bulb.................................................................................................................20271
Removal.............................................................................................................................20271
Installation........................................................................................................................20271
Courtesy Light Bulb.....................................................................................................................20271
Removal.............................................................................................................................20271
Installation........................................................................................................................20271
Map Light Switch/Bulb...................................................................................................................20272
Removal.............................................................................................................................20272
Installation........................................................................................................................20272
Ashtray Illumination Bulb...............................................................................................................20272
Removal.............................................................................................................................20272
Installation........................................................................................................................20272
Glove Box Illumination Bulb.............................................................................................................20273
Removal.............................................................................................................................20273
Installation........................................................................................................................20273
Vanity Mirror Illumination Bulb.........................................................................................................20273
Removal.............................................................................................................................20273
Installation........................................................................................................................20273
Starter Switch..........................................................................................................................20274
Removal.............................................................................................................................20274
Installation........................................................................................................................20274
Lighting Switch (Combination Switch)....................................................................................................20275
Removal.............................................................................................................................20275
Installation........................................................................................................................20275
Fog Light Switch........................................................................................................................20276
Removal.............................................................................................................................20276
Installation........................................................................................................................20276
Stoplight Switch (W/O Cruise Control)...................................................................................................20277
Removal.............................................................................................................................20277
Installation........................................................................................................................20277
Brake Switch (W/Cruise Control).........................................................................................................20278
Removal.............................................................................................................................20278
Installation........................................................................................................................20278
Turn Signal Switch/Cornering Light Switch (Combination Switch)..........................................................................20278
Removal and Installation............................................................................................................20278
Hazard Warning Switch...................................................................................................................20279
Removal.............................................................................................................................20279
Installation........................................................................................................................20279
Tailgate Switch.........................................................................................................................20280
Removal.............................................................................................................................20280
Installation........................................................................................................................20280
Door Switch.............................................................................................................................20280
Removal.............................................................................................................................20280
Installation........................................................................................................................20280
Rear Defogger Switch....................................................................................................................20281
Removal.............................................................................................................................20281
Installation........................................................................................................................20281
Seat Heater Switch......................................................................................................................20282
Removal.............................................................................................................................20282
Installation........................................................................................................................20282
Key Remind Switch (Starter Switch)......................................................................................................20282
Removal and Installation............................................................................................................20282
Illumination Controller.................................................................................................................20283
Removal.............................................................................................................................20283
Installation........................................................................................................................20283
Main Data and Specifications............................................................................................................20284
8B WIPER / WASHER SYSTEM....................................................................................................................20286
Service Precaution......................................................................................................................20286
Windshield Wiper/Washer System..........................................................................................................20287
General Description.....................................................................................................................20287
Windshield Wiper And Washer Switch......................................................................................................20287
Removal and Installation............................................................................................................20287
Windshield Wiper Motor..................................................................................................................20287
Removal.............................................................................................................................20287
Installation........................................................................................................................20287
Windshield Washer Motor.................................................................................................................20288
Removal.............................................................................................................................20288
Installation........................................................................................................................20288
Windshield Wiper Linkage................................................................................................................20289
Windshield Wiper Linkage and Associated Parts.......................................................................................20289
Removal.............................................................................................................................20289
Installation........................................................................................................................20289
Windshield Wiper Arm/Blade..............................................................................................................20290
Removal.............................................................................................................................20290
Installation........................................................................................................................20290
Windshield Wiper Blade Rubber...........................................................................................................20291
Removal.............................................................................................................................20291
Installation........................................................................................................................20291
Rear Wiper/Washer System................................................................................................................20292
General Description.....................................................................................................................20292
Rear Wiper and Washer Switch............................................................................................................20292
Removal.............................................................................................................................20292
Installation........................................................................................................................20292
Rear Wiper Motor........................................................................................................................20293
Removal.............................................................................................................................20293
Installation........................................................................................................................20293
Alarm & Relay Control Unit..............................................................................................................20294
Removal.............................................................................................................................20294
Installation........................................................................................................................20294
Rear Washer Motor.......................................................................................................................20294
Removal.............................................................................................................................20294
Installation........................................................................................................................20294
Rear Wiper Arm/Blade....................................................................................................................20295
Removal.............................................................................................................................20295
Installation........................................................................................................................20295
Rear Washer Nozzle......................................................................................................................20295
Removal.............................................................................................................................20295
Installation........................................................................................................................20295
Rear Washer Nozzle Angle Adjustment.................................................................................................20295
Rear Wiper Blade Rubber.................................................................................................................20296
Removal and Installation............................................................................................................20296
Main Data and Specifications............................................................................................................20296
8C ENTERTAINMENT............................................................................................................................20297
Service Precaution......................................................................................................................20297
Cigarette Lighter.......................................................................................................................20298
General Description.....................................................................................................................20298
Removal.............................................................................................................................20298
Installation........................................................................................................................20298
Digital Clock and Outside Temp..........................................................................................................20299
Removal.............................................................................................................................20299
Installation........................................................................................................................20299
Front ACC Socket........................................................................................................................20300
Removal.............................................................................................................................20300
Installation........................................................................................................................20300
Rear ACC Socket.........................................................................................................................20300
Removal.............................................................................................................................20300
Installation........................................................................................................................20300
Rod Type Antenna........................................................................................................................20301
Removal.............................................................................................................................20301
Installation........................................................................................................................20301
Diversity Glass Antenna.................................................................................................................20302
Glass Antenna System Parts Location.................................................................................................20302
Glass Antenna Pattern...................................................................................................................20303
Glass Antenna Amplifier Removal.....................................................................................................20303
Glass Antenna Amplifier Installation................................................................................................20303
Radio...................................................................................................................................20304
Removal.............................................................................................................................20304
Installation........................................................................................................................20304
Front Speaker...........................................................................................................................20305
Removal.............................................................................................................................20305
Installation........................................................................................................................20305
Tweeter Assembly........................................................................................................................20305
Removal.............................................................................................................................20305
Installation........................................................................................................................20305
Rear Speaker............................................................................................................................20306
Removal.............................................................................................................................20306
Installation........................................................................................................................20306
8D WIRING SYSTEM............................................................................................................................20307
Fuse, Relay and Diode...................................................................................................................20308
Relay and Fuse Box / Fuse Box Location..............................................................................................20308
Relay & Fuse Box....................................................................................................................20309
Fuse Box............................................................................................................................20310
Circuit Diagram.........................................................................................................................20311
8E METER AND GAUGE..........................................................................................................................20344
Service Precaution......................................................................................................................20344
General Description.....................................................................................................................20344
Meter Assembly..........................................................................................................................20345
General Description.....................................................................................................................20345
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights..................................................20345
Table for Meter/Gauge Connector Terminal Connections................................................................................20349
Removal.............................................................................................................................20353
Installation........................................................................................................................20353
Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb, A/T Indicator Light Bulb.............................................20353
Removal.............................................................................................................................20353
Installation........................................................................................................................20353
Vehicle Speed Sensor....................................................................................................................20354
Removal.............................................................................................................................20354
Installation........................................................................................................................20354
Fuel Tank Unit..........................................................................................................................20354
Removal.............................................................................................................................20354
Installation........................................................................................................................20354
Multi Meter.............................................................................................................................20355
Removal.............................................................................................................................20355
Installation........................................................................................................................20355
Ambient Sensor..........................................................................................................................20355
Removal.............................................................................................................................20355
Installation........................................................................................................................20355
Main Data and Specifications............................................................................................................20356
8F BODY STRUCTURE...........................................................................................................................20357
Service Precaution......................................................................................................................20359
Frame...................................................................................................................................20359
Frame Dimensions....................................................................................................................20360
General Description.................................................................................................................20361
Front Bumper............................................................................................................................20361
Parts Location......................................................................................................................20361
Removal.............................................................................................................................20362
Installation........................................................................................................................20362
Front Bumper Slider Bracket.............................................................................................................20362
Removal.............................................................................................................................20362
Installation........................................................................................................................20362
Rear Bumper.............................................................................................................................20363
Parts Location......................................................................................................................20363
Removal.............................................................................................................................20364
Installation........................................................................................................................20364
Rear Bumper Slider......................................................................................................................20365
Removal.............................................................................................................................20365
Installation........................................................................................................................20365
General Description.....................................................................................................................20366
Cowl Cover..............................................................................................................................20366
Parts Location......................................................................................................................20366
Removal.............................................................................................................................20367
Installation........................................................................................................................20367
Engine Hood.............................................................................................................................20367
Removal.............................................................................................................................20367
Installation........................................................................................................................20367
Engine Hood Hinge.......................................................................................................................20368
Parts Location......................................................................................................................20368
Removal.............................................................................................................................20368
Installation........................................................................................................................20368
Engine Hood Lock........................................................................................................................20369
Parts Location......................................................................................................................20369
Removal.............................................................................................................................20369
Installation........................................................................................................................20370
Radiator Grille And Front End Lower Panel...............................................................................................20370
Parts Location......................................................................................................................20370
Removal.............................................................................................................................20371
Installation........................................................................................................................20371
Front Fender Panel......................................................................................................................20372
Parts Location......................................................................................................................20372
Removal.............................................................................................................................20372
Installation........................................................................................................................20373
Body Mounting...........................................................................................................................20374
Parts Location......................................................................................................................20374
Removal (No.1 – No. 2)..............................................................................................................20374
Removal (No. 3 — No. 6).............................................................................................................20375
Installation........................................................................................................................20376
General Description.....................................................................................................................20377
Body Dimension..........................................................................................................................20378
Instrument Panel Assembly...............................................................................................................20396
Parts Location......................................................................................................................20396
Removal.............................................................................................................................20397
Installation........................................................................................................................20401
Cross Beam Assembly.....................................................................................................................20402
Parts Location......................................................................................................................20402
Removal.............................................................................................................................20402
Installation........................................................................................................................20403
Front Door Assembly.....................................................................................................................20404
Parts Location......................................................................................................................20404
Removal.............................................................................................................................20404
Installation........................................................................................................................20404
Rear Door Assembly......................................................................................................................20405
Parts Location......................................................................................................................20405
Removal.............................................................................................................................20405
Installation........................................................................................................................20406
Door Strikers...........................................................................................................................20406
Adjustment..........................................................................................................................20406
Door Check Arm Assembly (Front & Rear)..................................................................................................20407
Parts Location......................................................................................................................20407
Removal.............................................................................................................................20407
Installation........................................................................................................................20408
Front Window Regulator, Glass And Glass Run.............................................................................................20408
Parts Location......................................................................................................................20408
Removal.............................................................................................................................20408
Installation........................................................................................................................20410
Rear Window Regulator And Glass.........................................................................................................20411
Parts Location......................................................................................................................20411
Removal.............................................................................................................................20411
Installation........................................................................................................................20412
Rear Door Fixed Glass And Glass Run.....................................................................................................20413
Parts Location......................................................................................................................20413
Removal.............................................................................................................................20413
Installation........................................................................................................................20414
Front Door Sash Moulding................................................................................................................20415
Parts Location......................................................................................................................20415
Removal.............................................................................................................................20415
Installation........................................................................................................................20415
Rear Door Moulding......................................................................................................................20416
Parts Location......................................................................................................................20416
Removal.............................................................................................................................20416
Installation........................................................................................................................20416
Front Door Waist Seal...................................................................................................................20417
Parts Location......................................................................................................................20417
Removal.............................................................................................................................20417
Installation........................................................................................................................20417
Rear Door Waist Seal....................................................................................................................20418
Parts Location......................................................................................................................20418
Removal and Installation............................................................................................................20418
Front Door Weatherstrip.................................................................................................................20419
Parts Location......................................................................................................................20419
Removal.............................................................................................................................20419
Installation........................................................................................................................20420
Rear Door Weatherstrip..................................................................................................................20421
Parts Location......................................................................................................................20421
Removal and Installation............................................................................................................20421
Front Door Seal Finisher................................................................................................................20422
Parts Location......................................................................................................................20422
Removal.............................................................................................................................20422
Installation........................................................................................................................20422
Rear Door Seal Finisher.................................................................................................................20423
Parts Location......................................................................................................................20423
Removal.............................................................................................................................20423
Installation........................................................................................................................20423
Tailgate Assembly (LH)..................................................................................................................20424
Parts Location......................................................................................................................20424
Removal.............................................................................................................................20424
Installation........................................................................................................................20425
Tailgate Assembly (RH)..................................................................................................................20426
Parts Location......................................................................................................................20426
Removal.............................................................................................................................20426
Installation........................................................................................................................20427
Tailgate Strikers.......................................................................................................................20428
Adjustment..........................................................................................................................20428
Tailgate Stopper Assembly...............................................................................................................20428
Parts Location......................................................................................................................20428
Removal.............................................................................................................................20428
Installation........................................................................................................................20428
Tailgate Dove-Tail......................................................................................................................20429
Parts Location......................................................................................................................20429
Removal.............................................................................................................................20429
Installation........................................................................................................................20429
Tailgate Dove-Tail Striker..............................................................................................................20430
Adjustment..........................................................................................................................20430
Tailgate Frame Cover (LH)...............................................................................................................20431
Parts Location......................................................................................................................20431
Removal.............................................................................................................................20431
Installation........................................................................................................................20431
Tailgate Frame Cover (RH)...............................................................................................................20432
Removal.............................................................................................................................20432
Installation........................................................................................................................20432
Tailgate Sash Trim Cover................................................................................................................20433
Parts Location......................................................................................................................20433
Removal.............................................................................................................................20433
Installation........................................................................................................................20433
Tailgate Outer Weatherstrip.............................................................................................................20434
Parts Location......................................................................................................................20434
Removal.............................................................................................................................20434
Installation........................................................................................................................20434
Tailgate Center Weatherstrip............................................................................................................20435
Parts Location......................................................................................................................20435
Removal.............................................................................................................................20435
Installation........................................................................................................................20435
Tailgate Main Weatherstrip..............................................................................................................20436
Parts Location......................................................................................................................20436
Removal.............................................................................................................................20436
Installation........................................................................................................................20436
Spare Tire Carrier......................................................................................................................20437
Parts Location......................................................................................................................20437
Removal.............................................................................................................................20437
Installation........................................................................................................................20437
Headlining..............................................................................................................................20438
Parts Location......................................................................................................................20438
Removal.............................................................................................................................20438
Installation........................................................................................................................20439
Rear Air Deflector......................................................................................................................20440
Parts Location......................................................................................................................20440
Removal.............................................................................................................................20440
Installation........................................................................................................................20440
Roof Moulding...........................................................................................................................20442
Parts Location......................................................................................................................20442
Removal.............................................................................................................................20442
Installation........................................................................................................................20443
Windshield..............................................................................................................................20444
Parts Location......................................................................................................................20444
Removal.............................................................................................................................20444
Installation........................................................................................................................20445
Rear Quarter Side Glass.................................................................................................................20449
Parts Location......................................................................................................................20449
Removal.............................................................................................................................20449
Installation........................................................................................................................20449
Tailgate Glass..........................................................................................................................20451
Parts Location......................................................................................................................20451
Removal.............................................................................................................................20451
Installation........................................................................................................................20452
Main Data and Specifications............................................................................................................20453
Special Tools...........................................................................................................................20463
8G SEATS....................................................................................................................................20464
Service Precaution......................................................................................................................20464
Front Seat Assembly.....................................................................................................................20465
Front Seat Assembly and Associated Parts............................................................................................20465
Removal.............................................................................................................................20465
Installation........................................................................................................................20465
Disassembled View...................................................................................................................20466
Disassembly.........................................................................................................................20467
Reassembly..........................................................................................................................20468
Power Seat Assembly.....................................................................................................................20469
General Description.....................................................................................................................20469
Disassembled View...................................................................................................................20469
Disassembly.........................................................................................................................20470
Reassembly..........................................................................................................................20472
Power Seat Switch.......................................................................................................................20472
Removal.............................................................................................................................20472
Installation........................................................................................................................20472
Front Tilt Motor / Rear Tilt Motor / Slide Motor / Recliner Motor.......................................................................20473
Parts Location......................................................................................................................20473
Removal and Installation............................................................................................................20473
Seat Heater System......................................................................................................................20474
General Description.....................................................................................................................20474
Seat Heater Switch Removal and Installation.........................................................................................20474
Heat Unit Parts Location............................................................................................................20474
Heat Unit Removal and Installation..................................................................................................20474
Rear Seat Assembly......................................................................................................................20475
Rear Seat Assembly and Associated Parts.............................................................................................20475
Removal.............................................................................................................................20475
Installation........................................................................................................................20475
Disassembled View (Split Type)......................................................................................................20476
Disassembly (Split Type)............................................................................................................20477
Reassembly (Split Type).............................................................................................................20478
Disassembled View (Bench Type)......................................................................................................20479
Disassembly (Bench Type)............................................................................................................20480
Reassembly (Bench Type).............................................................................................................20481
Main Data and Specifications............................................................................................................20481
8H SECURITY AND LOCKS.......................................................................................................................20483
Service Precaution......................................................................................................................20484
Front Door Lock Assembly................................................................................................................20484
Front Door Lock Assembly and Associated Parts.......................................................................................20484
Removal.............................................................................................................................20485
Installation........................................................................................................................20485
Front Outside Handle and Door Lock Cylinder.............................................................................................20486
Front Outside Handle, Door Lock Cylinder and Associated Parts.......................................................................20486
Removal.............................................................................................................................20486
Installation........................................................................................................................20487
Rear Door Lock Assembly.................................................................................................................20489
Rear Door Lock Assembly and Associated Parts........................................................................................20489
Removal.............................................................................................................................20489
Installation........................................................................................................................20490
Rear Outside Handle.....................................................................................................................20491
Rear Outside Handle and Associated Parts............................................................................................20491
Removal.............................................................................................................................20491
Installation........................................................................................................................20492
Rear Door Inside Lock Knob Link.........................................................................................................20492
Removal.............................................................................................................................20492
Installation........................................................................................................................20492
Door Inside Lock Knob...................................................................................................................20493
Removal.............................................................................................................................20493
Installation........................................................................................................................20493
Door Inside Handle......................................................................................................................20493
Removal and Installation............................................................................................................20493
Tailgate Lock Assembly (LH).............................................................................................................20494
Tailgate Lock Assembly (LH) and Associated Parts....................................................................................20494
Removal.............................................................................................................................20494
Installation........................................................................................................................20495
Tailgate Lock Assembly (RH).............................................................................................................20496
Tailgate Lock Assembly (RH) and Associated Parts....................................................................................20496
Removal.............................................................................................................................20496
Installation........................................................................................................................20497
Tailgate Inside Lock Knob...............................................................................................................20497
Removal.............................................................................................................................20497
Installation........................................................................................................................20497
Tailgate Outside Handle and/or Tailgate Lock Cylinder...................................................................................20498
Tailgate Outside Handle and/or Tailgate Lock Cylinder and Associated Parts..........................................................20498
Removal.............................................................................................................................20498
Installation........................................................................................................................20499
Key.....................................................................................................................................20500
Key Coding..........................................................................................................................20500
Key Styles..........................................................................................................................20500
Power Door Lock System..................................................................................................................20501
General Description.....................................................................................................................20501
Front Door Lock Actuator Removal....................................................................................................20501
Front Door Lock Actuator Installation...............................................................................................20501
Rear Door Lock Actuator Removal.....................................................................................................20501
Rear Door Lock Actuator Installation................................................................................................20502
Tailgate Lock Actuator Removal......................................................................................................20502
Tailgate Lock Actuator Installation.................................................................................................20502
Anti-theft System.......................................................................................................................20503
General Description.....................................................................................................................20503
Anti-theft & Keyless Entry Control Unit Removal.....................................................................................20503
Anti-theft & Keyless Entry Control Unit Installation................................................................................20503
Anti-theft Indicator Removal........................................................................................................20503
Anti-theft Indicator Installation...................................................................................................20504
Anti-theft Horn Removal.............................................................................................................20504
Anti-Theft Horn Installation........................................................................................................20504
Engine Hood Switch Removal..........................................................................................................20504
Engine Hood Switch Installation.....................................................................................................20504
Keyless Entry System....................................................................................................................20505
ID Code Registration................................................................................................................20505
Anti‐theft & Keyless Entry Control Unit/Transmitter Replacement.....................................................................20507
Main Data and Specifications............................................................................................................20508
8I SUN ROOF/CONVERTIBLE TOP.................................................................................................................20509
Service Precaution......................................................................................................................20509
Sun Roof Glass..........................................................................................................................20510
Sun Roof Glass and Associated Parts.................................................................................................20510
Removal.............................................................................................................................20510
Installation........................................................................................................................20511
Sun Roof Deflector......................................................................................................................20512
Removal.............................................................................................................................20512
Installation........................................................................................................................20512
Sunshade................................................................................................................................20512
Disassembled View...................................................................................................................20512
Removal.............................................................................................................................20513
Installation........................................................................................................................20513
Sun Roof Frame Complete Assembly........................................................................................................20514
Sun Roof Frame Complete Assembly and Associated Parts...............................................................................20514
Removal.............................................................................................................................20514
Installation........................................................................................................................20515
Disassembled View...................................................................................................................20515
Disassembly.........................................................................................................................20515
Reassembly..........................................................................................................................20516
Sun Roof Drain Hose (Front Side)........................................................................................................20517
Sun Roof Drain Hose (Front Side) and Associated Parts...............................................................................20517
Removal.............................................................................................................................20517
Installation........................................................................................................................20517
Sun Roof Drain Hose (Rear Side).........................................................................................................20518
Sun Roof Drain Hose (Rear Side) and Associated Parts................................................................................20518
Removal.............................................................................................................................20518
Installation........................................................................................................................20518
Sun Roof Switch.........................................................................................................................20519
General Description.....................................................................................................................20519
Removal.............................................................................................................................20519
Installation........................................................................................................................20519
Sun Roof Motor..........................................................................................................................20520
Removal.............................................................................................................................20520
Installation........................................................................................................................20520
Main Data and Specifications............................................................................................................20521
8J EXTERIOR / INTERIOR TRIM.................................................................................................................20522
Service Precaution......................................................................................................................20523
Dash Side Trim Panel....................................................................................................................20524
Removal.............................................................................................................................20524
Installation........................................................................................................................20524
Assist Grip.............................................................................................................................20524
Parts Location......................................................................................................................20524
Removal and Installation............................................................................................................20524
Consoles................................................................................................................................20525
Consoles and Associated Parts.......................................................................................................20525
Removal.............................................................................................................................20525
Installation........................................................................................................................20526
Front Door Trim Panel...................................................................................................................20527
Front Door Trim Panel and Associated Parts..........................................................................................20527
Removal.............................................................................................................................20527
Installation........................................................................................................................20530
Rear Door Trim Panel....................................................................................................................20531
Rear Door Trim Panel and Associated Parts...........................................................................................20531
Removal.............................................................................................................................20531
Installation........................................................................................................................20532
Door Wood Panel Assembly................................................................................................................20534
Door Wood Panel Assembly and Associated Parts.......................................................................................20534
Removal.............................................................................................................................20534
Installation........................................................................................................................20534
Door Mirror.............................................................................................................................20535
Door Mirror and Associated Parts....................................................................................................20535
Removal.............................................................................................................................20535
Installation........................................................................................................................20535
Luggage Side and Quarter Upper Trim Cover...............................................................................................20536
Luggage Side, Quarter Upper Trim Cover and Associated Parts.........................................................................20536
Removal.............................................................................................................................20536
Installation........................................................................................................................20538
Center Pillar and Roof Side Trim Cover..................................................................................................20539
Center Pillar, Roof Side Trim Cover and Associated Parts............................................................................20539
Removal.............................................................................................................................20539
Installation........................................................................................................................20540
Front Pillar Trim Cover.................................................................................................................20541
Front Pillar Trim Cover and
Associated Parts.......................................................................................20541
Removal.............................................................................................................................20541
Installation........................................................................................................................20541
Center Pillar Assist Grip...............................................................................................................20542
Parts Location......................................................................................................................20542
Removal and Installation............................................................................................................20542
Assist Grip.............................................................................................................................20542
Parts Location......................................................................................................................20542
Removal and Installation............................................................................................................20542
Fuel Filler Lid Opener Cable............................................................................................................20543
Fuel Filler Lid Opener Cable and Associated Parts...................................................................................20543
Removal.............................................................................................................................20543
Installation........................................................................................................................20544
Fuel Filler Door........................................................................................................................20544
Parts Location......................................................................................................................20544
Removal.............................................................................................................................20544
Installation........................................................................................................................20544
Rocker Protector (Without Wheel Opening Extension)......................................................................................20545
Rocker Protector (Without Wheel Opening Extension) and Associated Parts.............................................................20545
Removal.............................................................................................................................20545
Installation........................................................................................................................20545
Wheel Opening Extension and Rocker Protector Assembly...................................................................................20546
Wheel Opening Extension, Rocker Protector Assembly and Associated Parts.............................................................20546
Removal.............................................................................................................................20546
Installation........................................................................................................................20547
Mud Flaps (With Wheel Opening Extension)................................................................................................20548
Mud Flaps (With Wheel Opening Extension) and Associated Parts.......................................................................20548
Removal.............................................................................................................................20548
Installation........................................................................................................................20548
Ventilation Assembly....................................................................................................................20549
Ventilation Assembly and Associated Parts...........................................................................................20549
Removal.............................................................................................................................20549
Installation........................................................................................................................20549
Tailgate Trim Panel (LH)................................................................................................................20550
Tailgate Trim Panel (LH) and Associated Parts.......................................................................................20550
Removal.............................................................................................................................20550
Installation........................................................................................................................20550
Tailgate Trim Panel (RH)................................................................................................................20551
Parts Location......................................................................................................................20551
Removal.............................................................................................................................20551
Installation........................................................................................................................20551
Luggage Floor Box.......................................................................................................................20552
Luggage Floor Box and Associated Parts..............................................................................................20552
Remove..............................................................................................................................20552
Installation........................................................................................................................20552
Rope Hook Set...........................................................................................................................20552
Rope Hook Set and Associated Parts..................................................................................................20552
Removal.............................................................................................................................20552
Installation........................................................................................................................20552
Power Door Mirror System................................................................................................................20553
General Description.....................................................................................................................20553
Door Mirror Switch Assembly (Control Switch, Folding Switch and Defogger Switch) Removal............................................20553
Installation........................................................................................................................20553
Power Door Mirror.......................................................................................................................20554
General Description.................................................................................................................20554
Removal and Installation............................................................................................................20554
Power Window System.....................................................................................................................20555
General Description.....................................................................................................................20555
Power Window Switch Removal and Installation........................................................................................20555
Power Window Motor Removal and Installation.........................................................................................20556
Main Data and Specifications............................................................................................................20557
Sec.9 RESTRAINTS................................................................................................................................20558
9A SEAT BELT SYSTEM.........................................................................................................................20558
Service Precaution......................................................................................................................20558
Seat Belt...............................................................................................................................20559
Front Seat Belt and Associated Parts................................................................................................20559
Removal.............................................................................................................................20559
Inspection..........................................................................................................................20559
Installation........................................................................................................................20560
Rear Seat Belt and Associated Parts.................................................................................................20560
Removal.............................................................................................................................20561
Inspection..........................................................................................................................20561
Installation........................................................................................................................20561
Front Seat Buckle Assembly..............................................................................................................20561
Removal.............................................................................................................................20561
Installation........................................................................................................................20561
Rear Center Seat Belt / Buckle Assembly.................................................................................................20562
Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................20562
Removal.............................................................................................................................20562
Installation........................................................................................................................20562
Rear Seat Lock Assembly.................................................................................................................20563
Removal.............................................................................................................................20563
Installation........................................................................................................................20563
Rear Seat Lock Assembly (Bench Type)....................................................................................................20563
Removal.............................................................................................................................20563
Installation........................................................................................................................20563
Rear Seat Strikers......................................................................................................................20564
Removal.............................................................................................................................20564
Installation........................................................................................................................20564
Child Seat Tether Anchor Bracket (Child Restraint)......................................................................................20564
General Description.....................................................................................................................20564
Child Seat Tether Anchor Bracket and Associated Parts...............................................................................20564
Installation........................................................................................................................20564
Main Data and Specifications............................................................................................................20565
9J SUPPLEMENTAL RESTRAINT SYSTEM............................................................................................................20566
Service Precaution......................................................................................................................20566
General Description.....................................................................................................................20567
SRS Component And Wiring Location View..................................................................................................20569
Component Description...................................................................................................................20569
Definitions.............................................................................................................................20572
Diagnosis...............................................................................................................................20573
SRS Connector Body Face Views...........................................................................................................20574
Repairs And Inspections Required After An Accident......................................................................................20574
On–Vehicle Service......................................................................................................................20575
Air Bag Assembly Handling /
Shipping / Scrapping.......................................................................................20576
Special Tools...........................................................................................................................20585
Service Precautions for SRS Component Service...........................................................................................20589
SRS Connectors..........................................................................................................................20590
Sensing And Diagnostic Module (SDM).....................................................................................................20592
Service Precautions.................................................................................................................20592
Removal.............................................................................................................................20592
Installation........................................................................................................................20592
Driver Air Bag Assembly.................................................................................................................20594
Service Precautions.................................................................................................................20594
Removal.............................................................................................................................20594
Installation........................................................................................................................20595
Steering Wheel..........................................................................................................................20596
Service Precautions.................................................................................................................20596
Removal.............................................................................................................................20596
Installation........................................................................................................................20597
SRS Coil Assembly.......................................................................................................................20599
Service Precautions.................................................................................................................20599
Removal.............................................................................................................................20599
Installation........................................................................................................................20600
Steering Column.........................................................................................................................20602
Service Precautions.................................................................................................................20602
Removal.............................................................................................................................20602
Installation........................................................................................................................20604
Passenger Air Bag Assembly..............................................................................................................20606
Service Precautions.................................................................................................................20606
Removal.............................................................................................................................20606
Installation........................................................................................................................20607
Main Data and Specifications............................................................................................................20607
9J1 RESTRAINT CONTROL SYSTEM................................................................................................................20608
Service Precaution......................................................................................................................20608
Diagnostic Information..................................................................................................................20609
System Schematic........................................................................................................................20611
SRS Diagnostic System Check.............................................................................................................20611
Chart A SDM Integrity Check.............................................................................................................20613
Chart B “AIR BAG” Warning Lamp Comes “ON” Steady........................................................................................20615
Chart C “AIR BAG” Warning Lamp Does Not Come “ON” Steady (1/2)..........................................................................20617
DTC 15 Passenger Deployment Loop Resistance High........................................................................................20620
DTC 16 Passenger Deployment loop Resistance Low.........................................................................................20622
DTC 17 Passenger Deployment Loop Open...................................................................................................20624
DTC 18 Passenger Deployment Loop Short To Ground........................................................................................20626
DTC 19 Passenger Deployment Loop Short To Voltage.......................................................................................20628
DTC 21 Driver Deployment Loop Resistance High...........................................................................................20630
DTC 22 Driver Deployment Loop Resistance Low............................................................................................20633
DTC 24 Driver Deployment Loop Short To Ground...........................................................................................20635
DTC 25 Driver Deployment Loop Short To Voltage..........................................................................................20637
DTC 26 Driver Deployment Loop Open......................................................................................................20639
DTC 51 Deployment Event Commanded.......................................................................................................20641
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range..................................................20643
DTC 61 Warning Lamp Circuit Failure.....................................................................................................20645
DTC 71 Internal SDM Fault...............................................................................................................20647
Sec.10 CONTROL SYSTEM...........................................................................................................................20649
10A CRUISE CONTROL SYSTEM...................................................................................................................20649
Service Precaution......................................................................................................................20649
General Description.....................................................................................................................20649
Brake Switch............................................................................................................................20650
Removal.............................................................................................................................20650
Installation........................................................................................................................20650
Adjustment..........................................................................................................................20651
Clutch Switch...........................................................................................................................20651
Removal and Installation............................................................................................................20651
Adjustment..........................................................................................................................20651
Starter Switch..........................................................................................................................20652
Removal.............................................................................................................................20652
Installation........................................................................................................................20652
Cruise Control Main Switch..............................................................................................................20653
Removal.............................................................................................................................20653
Installation........................................................................................................................20653
Cruise Control Switch (Combination Switch)..............................................................................................20653
Removal and Installation............................................................................................................20653
Powertrain Control Module (PCM).........................................................................................................20653
Removal and Installation............................................................................................................20653
Mode Switch.............................................................................................................................20653
Removal and Installation............................................................................................................20653
Diagnosis...............................................................................................................................20654
Diagnostic trouble cade.............................................................................................................20654
(UE) RODEO..........................................................................................................................................20655
Sec.0 GENERAL INFORMATION.......................................................................................................................20656
0A General Information......................................................................................................................20656
General Repair Instruction..............................................................................................................20656
Illustration Arrows.....................................................................................................................20657
Identification..........................................................................................................................20659
Theft Prevention Standard...............................................................................................................20662
Lifting Instructions....................................................................................................................20667
Standard Bolts Torque Specifications....................................................................................................20669
Abbreviations Charts....................................................................................................................20670
Service Parts Identification Plate......................................................................................................20672
0B Maintenance and Lubrication..............................................................................................................20673
Maintenance Schedule List...............................................................................................................20673
Explanation of Complete Vehicle Maintenance Schedule....................................................................................20677
Recommended Fluids and Lubricants...................................................................................................20680
Lubricant Viscosity Chart...............................................................................................................20681
Recommended Liquid Gasket...........................................................................................................20683
Recommended Thread Locking Agents...................................................................................................20683
Maintenance Service Data................................................................................................................20684
Sec.1 HEATING, VENTILATION AND AIR CONDITIONING.................................................................................................20685
1A HVAC SYSTEMS.............................................................................................................................20685
Service Precaution......................................................................................................................20686
Heating and Ventilation System..........................................................................................................20686
General Description.....................................................................................................................20686
Wiring Diagram..........................................................................................................................20690
Diagnosis...............................................................................................................................20691
Individual Inspection...................................................................................................................20695
Heater Unit.............................................................................................................................20697
Heater Unit and Associated Parts....................................................................................................20697
Removal.............................................................................................................................20697
Installation........................................................................................................................20698
Heater Core and / or Mode Door..........................................................................................................20698
Disassembled View...................................................................................................................20698
Removal.............................................................................................................................20699
Inspection..........................................................................................................................20699
Installation........................................................................................................................20699
Heater Mode Control Link Unit...........................................................................................................20700
Disassembled View...................................................................................................................20700
Removal.............................................................................................................................20700
Installation........................................................................................................................20701
Heater Temperature Control Link Unit....................................................................................................20701
Disassembled View...................................................................................................................20701
Removal.............................................................................................................................20701
Installation........................................................................................................................20702
Blower Assembly.........................................................................................................................20702
Blower Assembly and Associated Parts................................................................................................20702
Removal.............................................................................................................................20703
Installation........................................................................................................................20703
Blower Link Unit and / or Mode door.....................................................................................................20703
Disassembled View...................................................................................................................20703
Removal.............................................................................................................................20703
Installation........................................................................................................................20704
Blower Motor............................................................................................................................20705
Blower Motor and Associated Parts...................................................................................................20705
Removal.............................................................................................................................20705
Installation........................................................................................................................20705
Rear Heater Duct, Defroster Nozzle and Ventilation Duct.................................................................................20706
Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts...........................................................20706
Removal.............................................................................................................................20706
Installation........................................................................................................................20707
Control Lever Assembly and / or Control Cable...........................................................................................20707
Control Lever Assembly, Control Cable and Associated Parts..........................................................................20707
Removal.............................................................................................................................20708
Installation........................................................................................................................20709
Control Panel Illumination Bulb.........................................................................................................20710
Control Panel Illumination Bulb and Associated Parts................................................................................20710
Removal.............................................................................................................................20710
Installation........................................................................................................................20710
Resistor................................................................................................................................20710
Resistor and Associated Parts.......................................................................................................20710
Removal.............................................................................................................................20710
Installation........................................................................................................................20710
Air Conditioning System.................................................................................................................20711
General Description.....................................................................................................................20711
Diagnosis...............................................................................................................................20721
Air Source Select Lever Diagnosis.......................................................................................................20731
Air Conditioning System.................................................................................................................20734
Individual Inspection...............................................................................................................20734
General Repair Procedure............................................................................................................20735
Leak Check..........................................................................................................................20737
Compressor Assembly.....................................................................................................................20742
Compressor Assembly and Associated Parts (6VD1).....................................................................................20742
Removal.............................................................................................................................20742
Installation........................................................................................................................20743
New Compressor Installation.........................................................................................................20743
Compressor Assembly.....................................................................................................................20744
Compressor Assembly and Associated Parts (X22SE)....................................................................................20744
Removal.............................................................................................................................20744
Installation........................................................................................................................20745
New Compressor Installation.........................................................................................................20745
Condenser Assembly......................................................................................................................20746
Condenser Assembly and Associated Parts.............................................................................................20746
Removal.............................................................................................................................20746
Installation........................................................................................................................20746
Condenser Fan Motor.....................................................................................................................20747
Condenser Fan Motor and Associated Parts............................................................................................20747
Removal.............................................................................................................................20747
Installation........................................................................................................................20747
Receiver / Drier........................................................................................................................20748
Receiver / Drier and Associated Parts...............................................................................................20748
Removal.............................................................................................................................20748
Installation........................................................................................................................20748
Pressure Switch.........................................................................................................................20749
Pressure Switch and Associated Parts................................................................................................20749
Removal.............................................................................................................................20749
Installation........................................................................................................................20749
Evaporator Assembly.....................................................................................................................20750
Evaporator Assembly and Associated Parts............................................................................................20750
Removal.............................................................................................................................20750
Installation........................................................................................................................20751
Electronic Thermostat, Evaporator Core and/or Expansion Valve...........................................................................20752
Disassembled View...................................................................................................................20752
Removal.............................................................................................................................20752
Installation........................................................................................................................20753
Refrigerant Line........................................................................................................................20754
Refrigerant Line and Associated Parts...............................................................................................20754
Removal.............................................................................................................................20754
Installation........................................................................................................................20755
Main Data And Specifications............................................................................................................20756
Compressor..............................................................................................................................20759
Service Precaution..................................................................................................................20759
General Description.....................................................................................................................20759
Diagnosis...............................................................................................................................20760
Magnetic Clutch Assembly (DKV-14G Type).................................................................................................20761
Parts Location View.................................................................................................................20761
Removal.............................................................................................................................20761
Inspection and Repair...............................................................................................................20763
Installation........................................................................................................................20763
Compressor Oil..........................................................................................................................20765
Oil Specification...................................................................................................................20765
Handling of Oil.....................................................................................................................20765
Compressor Oil Check................................................................................................................20765
Checking and Adjusting Oil Quantity for Used Compressor.............................................................................20765
Checking and Adjusting for Compressor Replacement...................................................................................20766
Contamination of Compressor Oil.....................................................................................................20766
Oil Return Operation................................................................................................................20766
Replacement of Component Parts......................................................................................................20766
Main Data and Specifications............................................................................................................20767
Special Tools...........................................................................................................................20769
Sec.2 STEERING..................................................................................................................................20770
2A POWER-ASSISTED STEERING SYSTEM...........................................................................................................20770
Service Precaution......................................................................................................................20771
Diagnosis...........................................................................................................................20771
General Description.................................................................................................................20777
Power Steering System Test..........................................................................................................20779
Maintenance.........................................................................................................................20780
Fluid Level.........................................................................................................................20780
Bleeding The Power Steering System..................................................................................................20780
Bleeding Procedure..................................................................................................................20780
Flushing The Power Steering System..................................................................................................20780
Steering Wheel Free Play Inspection.................................................................................................20781
Front End Alignment Inspection and Adjustment.......................................................................................20781
Main Data and Specifications........................................................................................................20785
Special Tools.......................................................................................................................20786
Power Steering Unit.....................................................................................................................20787
Power Steering Unit and Associated Parts............................................................................................20787
Removal.............................................................................................................................20787
Installation (4x2 Model)............................................................................................................20788
Installation (4x4 Model)............................................................................................................20788
Power Steering Unit Disassembled View...............................................................................................20789
Disassembly.........................................................................................................................20790
Inspection and Repair...............................................................................................................20790
Reassembly..........................................................................................................................20790
Main Data and Specifications........................................................................................................20790
Special Tools.......................................................................................................................20791
Power Steering Pump.....................................................................................................................20792
Power Steering Pump and Associated Parts............................................................................................20792
Removal.............................................................................................................................20792
Installation........................................................................................................................20792
Power Steering Pump Disassembled View...............................................................................................20793
Disassembly.........................................................................................................................20793
Inspection and Repair...............................................................................................................20794
Reassembly..........................................................................................................................20794
Main Data and Specifications........................................................................................................20796
Transfer Gear Assembly..................................................................................................................20797
Transfer Gear Assembly and Associated Parts.........................................................................................20797
Removal.............................................................................................................................20797
Inspection and Repair...............................................................................................................20797
Installation........................................................................................................................20797
Supplemental Restraint System Steering Wheel & Column...................................................................................20798
Service Precaution..................................................................................................................20798
SRS Connectors......................................................................................................................20798
Inflator Module.........................................................................................................................20800
Inflator Module and Associated Parts................................................................................................20800
Removal.............................................................................................................................20800
Inspection and Repair...............................................................................................................20801
Installation........................................................................................................................20801
Steering Wheel..........................................................................................................................20802
Steering Wheel and Associated Parts.................................................................................................20802
Removal.............................................................................................................................20802
Installation........................................................................................................................20804
Combination Switch......................................................................................................................20805
Combination Switch and Associated Parts.............................................................................................20805
Removal.............................................................................................................................20805
Installation........................................................................................................................20807
Lock Cylinder...........................................................................................................................20809
Lock Cylinder and Associated Parts..................................................................................................20809
Removal.............................................................................................................................20809
Installation........................................................................................................................20811
System Inspection...................................................................................................................20812
Steering Column.........................................................................................................................20813
Steering Column and Associated Parts................................................................................................20813
Removal.............................................................................................................................20813
Insepction..........................................................................................................................20815
Installation........................................................................................................................20817
System Inspection...................................................................................................................20818
Supplemental Restraint System Steering Wheel & Column and Associated Parts..............................................................20819
Main Data and Specifications............................................................................................................20819
Special Tools.......................................................................................................................20819
Sec.3 SUSPENSION................................................................................................................................20820
3C FRONT SUSPENSION.........................................................................................................................20820
Service Precaution......................................................................................................................20820
General Description.................................................................................................................20821
Diagnosis...........................................................................................................................20821
Shock Absorber..........................................................................................................................20825
Shock Absorber and Associated Parts.................................................................................................20825
Removal.............................................................................................................................20825
Inspection and Repair...............................................................................................................20825
Installation........................................................................................................................20825
Stabilizer Bar..........................................................................................................................20826
Stabilizer Bar and Associated Parts.................................................................................................20826
Removal.............................................................................................................................20826
Inspection and Repair...............................................................................................................20826
Installation........................................................................................................................20826
Torsion Bar.............................................................................................................................20827
Torsion Bar and Associated Parts....................................................................................................20827
Removal.............................................................................................................................20827
Inspection and Repair...............................................................................................................20828
Installation........................................................................................................................20828
Knuckle.................................................................................................................................20830
Knuckle and Associated Parts........................................................................................................20830
Removal.............................................................................................................................20830
Inspection and Repair...............................................................................................................20831
Installation........................................................................................................................20831
Upper Control Arm.......................................................................................................................20832
Upper Control Arm and Associated Parts..............................................................................................20832
Removal.............................................................................................................................20832
Inspection and Repair...............................................................................................................20833
Installation........................................................................................................................20833
Lower Control Arm.......................................................................................................................20835
Lower Control Arm and Associated Parts..............................................................................................20835
Removal.............................................................................................................................20835
Inspection and Repair...............................................................................................................20836
Installation........................................................................................................................20837
Upper Ball Joint........................................................................................................................20838
Upper Ball Joint and Associated Parts...............................................................................................20838
Removal.............................................................................................................................20838
Inspection and Repair...............................................................................................................20839
Installation........................................................................................................................20839
Lower Ball Joint........................................................................................................................20840
Lower Ball Joint and Associated Parts...............................................................................................20840
Removal.............................................................................................................................20840
Inspection and Repair...............................................................................................................20841
Installation........................................................................................................................20841
Main Data and Specifications............................................................................................................20842
Special Tools.......................................................................................................................20844
3D REAR SUSPENSION..........................................................................................................................20845
Service Precaution......................................................................................................................20845
General Description.................................................................................................................20845
Diagnosis...........................................................................................................................20846
Coil Spring.............................................................................................................................20849
Coil Spring and Associated Parts....................................................................................................20849
Removal.............................................................................................................................20849
Inspection and Repair...............................................................................................................20850
Installation........................................................................................................................20850
Shock Absorber..........................................................................................................................20851
Shock Absorber and Associated Parts.................................................................................................20851
Removal.............................................................................................................................20851
Inspection and Repair...............................................................................................................20851
Installation........................................................................................................................20851
Trailing Link...........................................................................................................................20852
Trailing Link and Associated Parts..................................................................................................20852
Removal.............................................................................................................................20852
Inspection and Repair...............................................................................................................20852
Installation........................................................................................................................20853
Upper Link..............................................................................................................................20854
Upper Link and Associated Parts.....................................................................................................20854
Removal.............................................................................................................................20854
Inspection and Repair...............................................................................................................20854
Installation........................................................................................................................20855
Lateral Rod.............................................................................................................................20856
Lateral Rod and Associated Parts....................................................................................................20856
Removal.............................................................................................................................20856
Inspection and Repair...............................................................................................................20856
Installation........................................................................................................................20857
Stabilizer Bar..........................................................................................................................20858
Stabilizer Bar and Associated Parts.................................................................................................20858
Removal.............................................................................................................................20858
Inspection and Repair...............................................................................................................20858
Installation........................................................................................................................20859
Main Data and Specifications............................................................................................................20860
Special Tools...........................................................................................................................20862
3E WHEEL AND TIRE SYSTEM....................................................................................................................20863
Service Precaution......................................................................................................................20863
General Description.................................................................................................................20864
Diagnosis...........................................................................................................................20865
Wheel...................................................................................................................................20873
Wheel and Associated Parts..........................................................................................................20873
Removal.............................................................................................................................20873
Installation........................................................................................................................20873
Tire....................................................................................................................................20874
Tire Replacement....................................................................................................................20874
General Balance Procedure...........................................................................................................20874
Balancing Wheel and Tire............................................................................................................20875
Main Data and Specifications............................................................................................................20876
3F INTELLIGENT SUSPENSION CONTROL...........................................................................................................20877
Service Precaution......................................................................................................................20877
General Description.................................................................................................................20877
General Diagnosis...................................................................................................................20880
DTC2 Actuator Coil Over Current.....................................................................................................20892
DTC3 Actuator Coil/Position Sensor Open Circuit or Short............................................................................20894
DTC4 G-Sensor Open Circuit or Short.................................................................................................20897
DTC5 Vehicle Speed Sensor Open Circuit or Short.....................................................................................20898
DTC6 Stop Lamp Switch Open Circuit or Short.........................................................................................20900
DTC7 Engine Speed Signal Open Circuit or Short......................................................................................20902
Control Unit............................................................................................................................20907
Removal.............................................................................................................................20907
Installation........................................................................................................................20908
Front Actuator..........................................................................................................................20909
Removal.............................................................................................................................20910
Inspection and Repair...............................................................................................................20910
Installation........................................................................................................................20910
Rear Shock Absorber.....................................................................................................................20911
Removal.............................................................................................................................20912
Inspection and Repair...............................................................................................................20912
Installation........................................................................................................................20912
Sec.4 DRIVELINE/AXLE............................................................................................................................20913
4A1 DIFFERENTIAL (FRONT)....................................................................................................................20913
Service Precaution......................................................................................................................20913
Front Drive Axle....................................................................................................................20914
Diagnosis...........................................................................................................................20914
Pinion Shaft Oil Seal...................................................................................................................20915
Pinion Shaft Oil Seal and Associated Parts..........................................................................................20915
Removal.............................................................................................................................20915
Inspection and Repair...............................................................................................................20916
Installation........................................................................................................................20916
Front Drive Axle Assembly...............................................................................................................20917
Front Drive Axle Assembly and Associated Parts......................................................................................20917
Removal.............................................................................................................................20918
Installation........................................................................................................................20918
Differential Assembly...................................................................................................................20920
Disassembled View...................................................................................................................20920
Disassembly.........................................................................................................................20921
Reassembly..........................................................................................................................20923
Differential Cage Assembly..............................................................................................................20931
Disassembled View...................................................................................................................20931
Disassembly.........................................................................................................................20931
Inspection and Repair...............................................................................................................20932
Reassembly..........................................................................................................................20932
Main Data and Specifications............................................................................................................20934
Special Tools.......................................................................................................................20937
4A2 Differential (Rear).....................................................................................................................20939
Service Precaution......................................................................................................................20939
General Description.....................................................................................................................20940
Diagnosis...............................................................................................................................20941
Axle Housing............................................................................................................................20943
Axle Housing and Associated Parts...................................................................................................20943
Removal.............................................................................................................................20943
Installation........................................................................................................................20945
Axle Shaft, Oil Seal and Bearing........................................................................................................20945
Axle Shaft and Associated Parts.....................................................................................................20945
Removal.............................................................................................................................20946
Inspection..........................................................................................................................20946
Installation........................................................................................................................20946
Pinion Oil Seal.........................................................................................................................20948
Pinion Oil Seal and Associated Parts................................................................................................20948
Removal.............................................................................................................................20948
Inspection and Repair...............................................................................................................20949
Installation........................................................................................................................20949
Differential Assembly...................................................................................................................20951
Disassembled View...................................................................................................................20951
Inspecting the Axle Before Disassembly..............................................................................................20952
Disassembly.........................................................................................................................20952
Inspection and Repair...............................................................................................................20954
Reassembly..........................................................................................................................20955
Side Bearing Preload Adjustment.....................................................................................................20959
Pinion Installation.................................................................................................................20960
Determination of Backlash & Preload Shims...........................................................................................20961
Backlash Adjustment.................................................................................................................20962
Gear Tooth Pattern Check............................................................................................................20963
Adjustments Affecting Tooth Contact.................................................................................................20964
Differential Case Assembly..............................................................................................................20964
Disassembled View...................................................................................................................20964
Disassembly.........................................................................................................................20965
Inspection and Repair...............................................................................................................20965
Reassembly..........................................................................................................................20965
Limited Slip Differential Assembly......................................................................................................20966
Disassembled View...................................................................................................................20966
Disassembly.........................................................................................................................20966
Inspection and Repair...............................................................................................................20968
Reassembly..........................................................................................................................20968
Main Data And Specifications............................................................................................................20970
Special Tools.......................................................................................................................20972
4B DRIVELINE CONTROL SYSTEM.................................................................................................................20974
Service Precaution......................................................................................................................20974
Shift On The Fly System.................................................................................................................20975
Outline of Shift on The Fly System..................................................................................................20975
Functions of Indicator Lamp.........................................................................................................20979
Diagnosis...........................................................................................................................20980
Shift On The Fly Electrical Equipment...................................................................................................20990
Axle Shaft Connection and Disconnection.............................................................................................20990
Actuator Assembly...................................................................................................................20990
4WD Control Unit........................................................................................................................20993
4WD Control Unit Associated Parts...................................................................................................20993
Removal.............................................................................................................................20993
Installation........................................................................................................................20994
Shift On The Fly Controller.............................................................................................................20994
Shift On The Fly Controller and Associated Parts....................................................................................20994
Removal.............................................................................................................................20994
Installation........................................................................................................................20994
4C DRIVE SHAFT SYSTEM.......................................................................................................................20995
Service Precaution......................................................................................................................20995
General Description.................................................................................................................20996
Diagnosis...........................................................................................................................20996
Front Hub and Disc (2WD Model)..........................................................................................................20997
Disassembled View...................................................................................................................20997
Disassembly.........................................................................................................................20997
Inspection..........................................................................................................................20998
Reassembly..........................................................................................................................20999
Front Hub and Disc (4WD Model)..........................................................................................................21000
Disassembled View...................................................................................................................21000
Disassembly.........................................................................................................................21000
Inspection..........................................................................................................................21001
Reassembly..........................................................................................................................21002
Front Drive Shaft Joint.................................................................................................................21003
Front Drive Shaft Joints Replacement................................................................................................21003
Front Axle Drive Shaft..................................................................................................................21004
Front Axle Drive Shaft and Associated Parts.........................................................................................21004
Disassembly.........................................................................................................................21005
Inspection And Repair...............................................................................................................21006
Bushing Replacement.................................................................................................................21006
Reassembly..........................................................................................................................21007
Shift On The Fly System.................................................................................................................21010
Shift On The Fly System and Associated Parts........................................................................................21010
Disassembly.........................................................................................................................21011
Inspection And Repair...............................................................................................................21012
Reassembly..........................................................................................................................21014
Main Data and Specifications............................................................................................................21017
Special Tools.......................................................................................................................21019
Propeller Shaft.........................................................................................................................21020
General Description.................................................................................................................21020
Universal Joint.....................................................................................................................21021
Diagnosis of Propeller Shaft and Universal Joint....................................................................................21022
Front Propeller Shaft...................................................................................................................21023
Front Propeller Shaft and Associated Parts..........................................................................................21023
Removal.............................................................................................................................21023
Installation........................................................................................................................21023
Disassembly.........................................................................................................................21024
Universal Joint Disassembly.........................................................................................................21025
Inspection and Repair...............................................................................................................21026
Universal Joint Reassembly..........................................................................................................21027
Reassembly..........................................................................................................................21028
Main Data and Specifications........................................................................................................21029
Rear Propeller Shaft....................................................................................................................21030
Rear Propeller Shaft and Associated Parts...........................................................................................21030
Removal.............................................................................................................................21030
Installation........................................................................................................................21030
Slip Joint Disassembly..............................................................................................................21031
Universal Joint Disassembly.........................................................................................................21032
Inspection..........................................................................................................................21034
Universal Joint Reassembly..........................................................................................................21035
Slip Joint Reassembly...............................................................................................................21036
Main Data and Specifications............................................................................................................21037
4D TRANSFER CASE............................................................................................................................21038
Service Precaution...................................................................................................................... 0
General Description................................................................................................................. 0
Transfer Rear Oil Seal.................................................................................................................. 0
Transfer Rear Oil Seal and Associated Parts......................................................................................... 0
Removal............................................................................................................................. 0
Installation........................................................................................................................ 0
Transfer Case Assembly (A/T)............................................................................................................ 0
Transfer Case Assembly (A/T) and Associated Parts................................................................................... 0
Removal............................................................................................................................. 0
Installation........................................................................................................................ 0
Transfer Rear Case Assembly (A/T)....................................................................................................... 0
Transfer Rear Case Assembly (A/T) and Associated Parts.............................................................................. 0
Removal............................................................................................................................. 0
Installation........................................................................................................................ 0
Transfer Rear Cover Assembly........................................................................................................ 0
Disassembly......................................................................................................................... 0
Inspection and Repair
262RW021..................................................................................................... 0
Reassembly.......................................................................................................................... 0
Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)........................................................................... 0
Disassembled View................................................................................................................... 0
Disassembly......................................................................................................................... 0
Inspection and Repair............................................................................................................... 0
Reassembly.......................................................................................................................... 0
Transfer Case Assembly.................................................................................................................. 0
Disassembled View................................................................................................................... 0
Disassembly......................................................................................................................... 0
Inspection and Repair............................................................................................................... 0
Reassembly.......................................................................................................................... 0
Main Data and Specifications............................................................................................................ 0
Special Tools....................................................................................................................... 0
Sec.5 BRAKES....................................................................................................................................21078
5A Brake Control System.....................................................................................................................21078
Service Precaution......................................................................................................................21079
General Description.....................................................................................................................21080
Functional Description..............................................................................................................21081
System Components...................................................................................................................21087
Electronic Hydraulic Control Unit (EHCU)............................................................................................21087
ABS Warning Light...................................................................................................................21087
Wheel Speed Sensor..................................................................................................................21087
G-Sensor............................................................................................................................21087
Normal and Anti-lock Braking........................................................................................................21087
Brake Pedal Travel..................................................................................................................21088
Acronyms and Abbreviations..........................................................................................................21088
General Diagnosis.......................................................................................................................21088
General Information.................................................................................................................21088
ABS Service Precautions.............................................................................................................21088
Computer System Service Precautions.................................................................................................21088
General Service Precautions.........................................................................................................21089
Note on Intermittents...............................................................................................................21089
Test Driving ABS Complaint Vehicles.................................................................................................21089
“ABS” Warning Light.................................................................................................................21089
Normal Operation....................................................................................................................21089
Tech 2 Scan Tool....................................................................................................................21090
DATA LIST...........................................................................................................................21093
ACTUATOR TEST.......................................................................................................................21094
Tech 2 Service Bleed................................................................................................................21098
Basic Diagnostic Flow Chart.........................................................................................................21099
Basic Inspection Procedure..........................................................................................................21100
EHCU Connector Pin-out Checks...........................................................................................................21101
Circuit Diagram.....................................................................................................................21102
Connector List......................................................................................................................21105
Part Location.......................................................................................................................21107
Symptom Diagnosis.......................................................................................................................21108
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate......................................................................21108
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................21109
Chart A-2 Uneven Braking Occurs While ABS Works.....................................................................................21109
Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2).......................................................................21109
Chart A-3, TA-3 The Wheels Are Locked...............................................................................................21110
Chart A-4 Brake Pedal Feed Is Abnormal..............................................................................................21110
Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................21111
Diagnostic Trouble Codes............................................................................................................21112
Diagnosis By “ABS” Warning Light Illumination Pattern...............................................................................21114
Diagnostic Trouble Codes (DTCs).....................................................................................................21115
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................21117
Chart B-2 CPU Error.................................................................................................................21117
Chart B-3 Low or High Ignition Voltage..............................................................................................21118
Chart B-4 Excessive Dump Time.......................................................................................................21118
Chart B-5 Excessive Isolation Time..................................................................................................21118
Chart B-6 G-Sensor Output Failure...................................................................................................21119
Chart B-7 Brake Switch Failure......................................................................................................21119
Chart B-8 2WD Controller in 4WD Vehicle Controller, 4WD State Input Signal Failure..................................................21120
Chart B-9 Pump Motor Failure........................................................................................................21120
Chart B-10 EHCU Valve Relay Failure.................................................................................................21121
Chart B-11 FL Isolation Solenoid Coil Failure.......................................................................................21121
Chart B-12 FL Dump Solenoid Coil Failure............................................................................................21121
Chart B-13 FR Isolation Solenoid Coil Failure.......................................................................................21122
Chart B-14 FR Dump Solenoid Coil Failure............................................................................................21122
Chart B-15 Rear Isolation Solenoid Coil Failure.....................................................................................21122
Chart B-16 Rear Dump Solenoid Coil Failure..........................................................................................21123
Chart B-17 FL Speed Sensor Open or Shorted..........................................................................................21123
Chart B-18 FR Speed Sensor Open or Shorted..........................................................................................21124
Chart B-19 Rear Speed Sensor Open or Shorted........................................................................................21125
Chart B-20 FL Speed Sensor Missing Signal...........................................................................................21126
Chart B-21 FR Speed Sensor Missing Signal...........................................................................................21127
Chart B-22 Rear Speed Sensor Missing Signal.........................................................................................21128
Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal.......................................................................21129
Chart B-24 Wheel Speed Input Abnormality............................................................................................21130
Unit Inspection Procedure...........................................................................................................21131
Chart C-1-1 FL Sensor Output Inspection Procedure...................................................................................21131
Chart C-1-2 FR Sensor Output Inspection Procedure...................................................................................21132
Chart C-1-3 Rear Sensor Output Inspection Procedure.................................................................................21132
Chart TC-1 Sensor Output Inspection Procedure.......................................................................................21133
Special Tools...........................................................................................................................21134
5B ANTI-LOCK BRAKE SYSTEM...................................................................................................................21135
Service Precaution......................................................................................................................21135
Electronic Hydraulic Control Unit.......................................................................................................21136
Electronic Hydraulic Control Unit and Associated Parts..............................................................................21136
Removal.............................................................................................................................21136
Disassembled View...................................................................................................................21137
Disassembly.........................................................................................................................21137
Reassembly..........................................................................................................................21137
Installation........................................................................................................................21137
Front Wheel Speed Sensor................................................................................................................21138
Front Wheel Speed Sensor and Associated Parts.......................................................................................21138
Removal.............................................................................................................................21138
Inspection and Repair...............................................................................................................21138
Installation........................................................................................................................21139
Rear Wheel Speed Sensor.................................................................................................................21139
Removal.............................................................................................................................21139
Inspection and Repair...............................................................................................................21139
Installation........................................................................................................................21139
5C POWER-ASSISTED BRAKE SYSTEM..............................................................................................................21140
Service Precaution......................................................................................................................21141
General Description.....................................................................................................................21141
Diagnosis...............................................................................................................................21145
General Diagnosis.......................................................................................................................21146
Hydraulic Brakes........................................................................................................................21149
Filling Master Cylinder Reservoir...................................................................................................21149
Deterioration of Brake Fluid........................................................................................................21149
Leakage of Brake Fluid..............................................................................................................21149
Bleeding Brake Hydraulic System.....................................................................................................21149
Flushing Brake Hydraulic System.....................................................................................................21150
Brake Pipes and Hoses...............................................................................................................21150
Brake Hose Inspection...............................................................................................................21151
Front Caliper Brake Hose................................................................................................................21151
Front Caliper Brake Hose and Associated Parts.......................................................................................21151
Removal.............................................................................................................................21151
Installation........................................................................................................................21151
Rear Axle Brake Hose....................................................................................................................21152
Rear Axle Brake Hose and Associated Parts...........................................................................................21152
Removal.............................................................................................................................21152
Installation........................................................................................................................21152
Brake Pipe..............................................................................................................................21153
Removal.............................................................................................................................21153
Installation........................................................................................................................21153
P & B (Proportioning and Bypass) Valve..................................................................................................21154
P & B (Proportioning and Bypass) Valve Sectional View...............................................................................21154
Removal.............................................................................................................................21154
Installation........................................................................................................................21154
Main Data and Specifications........................................................................................................21155
Brake Pedal.............................................................................................................................21156
Checking Pedal Height...............................................................................................................21156
Checking Pedal Travel...............................................................................................................21156
Brake Pedal and Associated Parts....................................................................................................21157
Removal.............................................................................................................................21157
Installation........................................................................................................................21157
Stoplight Switch........................................................................................................................21158
Parts Location......................................................................................................................21158
Removal.............................................................................................................................21158
Installation........................................................................................................................21158
Main Data and Specifications........................................................................................................21159
Master Cylinder Assembly................................................................................................................21160
Master Cylinder Assembly and Associated Parts.......................................................................................21160
Removal.............................................................................................................................21160
Inspection..........................................................................................................................21160
Master Cylinder Assembly................................................................................................................21161
Master Cylinder Assembly Desassembled View..........................................................................................21161
Desassembly.........................................................................................................................21161
Inspection..........................................................................................................................21161
Reassembly..........................................................................................................................21162
Installation........................................................................................................................21162
Main Data and Specifications............................................................................................................21163
Vacuum Booster Assembly.................................................................................................................21164
Vacuum Booster Assembly and Associated Parts........................................................................................21164
Removal.............................................................................................................................21164
Inspection and Repair...............................................................................................................21165
Exterior Components.....................................................................................................................21166
Exterior Components and Associated Parts............................................................................................21166
Removal.............................................................................................................................21166
Inspection and Repair...............................................................................................................21167
Installation........................................................................................................................21167
Vacuum Booster Overhaul.................................................................................................................21167
Vacuum Booster......................................................................................................................21167
Main Data and Specifications........................................................................................................21168
Front Disc Brake Pads...................................................................................................................21169
Front Disc Brake Pads Inspection....................................................................................................21169
Front Disc Brake Pads and Associated Parts..........................................................................................21169
Removal.............................................................................................................................21170
Installation........................................................................................................................21170
Front Disc Brake Rotor..................................................................................................................21172
Inspection..........................................................................................................................21172
Replacing Brake Rotors..............................................................................................................21172
Refinishing Brake Rotors............................................................................................................21172
Front Disc Brake Caliper Assembly.......................................................................................................21174
Front Disc Brake Caliper Assembly and Associated Parts..............................................................................21174
Removal.............................................................................................................................21174
Installation........................................................................................................................21175
Front Disc Brake Caliper................................................................................................................21177
Front Disc Brake Caliper Disassembled View..........................................................................................21177
Disassembly.........................................................................................................................21177
Inspection and Repair...............................................................................................................21178
Reassembly..........................................................................................................................21178
Main Data and Specifications........................................................................................................21179
Rear Disc Brake Pads (4x4 Model)........................................................................................................21180
Brake Pads Inspection...............................................................................................................21180
Brake Pads and Associated Parts.....................................................................................................21180
Removal.............................................................................................................................21181
Installation........................................................................................................................21181
Rear Disc Brake Rotor (4x4 Model).......................................................................................................21183
Inspection..........................................................................................................................21183
Replacing Brake Rotors..............................................................................................................21183
Refinishing Brake Rotors............................................................................................................21183
Rear Drum (In Disc) Inside Diameter Check...........................................................................................21184
Rear Disc Brake Caliper Assembly (4x4 Model)............................................................................................21185
Rear Disc Brake Caliper Assembly and Associated Parts...............................................................................21185
Removal.............................................................................................................................21185
Installation........................................................................................................................21186
Rear Disc Brake Caliper (4x4 Model).....................................................................................................21187
Rear Disc Brake Caliper Disassembled View...........................................................................................21187
Disassembly.........................................................................................................................21188
Inspection and Repair...............................................................................................................21188
Reassembly..........................................................................................................................21188
Main Data and Specifications (4x4 Model)............................................................................................21190
Brake Lining............................................................................................................................21191
Brake Lining and Associated Parts...................................................................................................21191
Removal.............................................................................................................................21191
Brake Lining Inspection.............................................................................................................21192
Installation........................................................................................................................21192
Drum Brake Adjustment (4x2 Model)...................................................................................................21193
Servicing The Brake Drum............................................................................................................21193
Wheel Cylinder Assembly (4x2 Model).....................................................................................................21194
Wheel Cylinder Assembly and Associated Parts........................................................................................21194
Removal.............................................................................................................................21194
Installation........................................................................................................................21194
Disassembled View...................................................................................................................21195
Disassembly.........................................................................................................................21195
Inspection and Repair...............................................................................................................21195
Reassembly..........................................................................................................................21195
Main Data and Specifications............................................................................................................21197
5D1 PARKING BRAKE SYSTEM (4x4 Model)........................................................................................................21198
Service Precaution......................................................................................................................21198
General Description.....................................................................................................................21198
Operation...............................................................................................................................21199
Parking Brake Lever and Front Cable.....................................................................................................21200
Parking Brake Lever Assembly and Associated Parts...................................................................................21200
Removal.............................................................................................................................21200
Installation........................................................................................................................21200
Parking Brake Rear Cable................................................................................................................21201
Parking Brake Rear Cable and Associated Parts.......................................................................................21201
Removal.............................................................................................................................21202
Installation........................................................................................................................21202
Inspection and Repair...............................................................................................................21203
Parking Brake Adjustment................................................................................................................21203
Main Data and Specifications............................................................................................................21204
5D2 PARKING BRAKE SYSTEM (4x2 Model)........................................................................................................21205
Service Precaution......................................................................................................................21205
General Description.....................................................................................................................21205
Parking Brake Lever.....................................................................................................................21206
Parking Brake Lever Assembly and Associated Parts...................................................................................21206
Removal.............................................................................................................................21206
Installation........................................................................................................................21206
Parking Brake Rear Cable................................................................................................................21207
Parking Brake Rear Cable and Associated Parts.......................................................................................21207
Removal.............................................................................................................................21208
Installation........................................................................................................................21208
Parking Brake Adjustment............................................................................................................21208
Main Data and Specifications............................................................................................................21209
Sec.6 ENGINE....................................................................................................................................21210
Y22SE 2.2L ENGINE..........................................................................................................................21210
6A ENGINE MECHANICAL....................................................................................................................21210
Service Precaution..................................................................................................................21211
General Description.................................................................................................................21211
Engine Diagnosis....................................................................................................................21212
Cylinder Head Cover.................................................................................................................21225
Cylinder Head Cover and Associated Parts........................................................................................21225
Removal.........................................................................................................................21225
Installation....................................................................................................................21226
Exhaust Manifold....................................................................................................................21228
Removal.........................................................................................................................21228
Installation....................................................................................................................21228
Crankshaft Pulley...................................................................................................................21229
Removal.........................................................................................................................21229
Installation....................................................................................................................21229
Intake Manifold.....................................................................................................................21230
Removal.........................................................................................................................21230
Installation....................................................................................................................21231
Cylinder Head Assembly..............................................................................................................21233
Removal.........................................................................................................................21233
Installation....................................................................................................................21235
Timing Belt.........................................................................................................................21238
Removal.........................................................................................................................21238
Installation....................................................................................................................21238
Camshaft............................................................................................................................21244
Camshaft and Associated Parts...................................................................................................21244
Removal.........................................................................................................................21244
Installation....................................................................................................................21245
Engine Assembly.....................................................................................................................21248
Removal.........................................................................................................................21248
Installation....................................................................................................................21250
Cylinder Head.......................................................................................................................21252
Cylinder Head and Associated Parts..............................................................................................21252
Disassembly.....................................................................................................................21252
Inspection and Repair...........................................................................................................21253
Reassembly......................................................................................................................21254
Valve Spring, Valve, Valve Guide....................................................................................................21255
Valve Spring, Valve, Valve Guide and Associated Parts...........................................................................21255
Disassembly.....................................................................................................................21256
Inspection and Repair...........................................................................................................21256
Reassembly......................................................................................................................21257
Crankshaft..........................................................................................................................21258
Crankshaft and Associated Parts.................................................................................................21258
Disassembly.....................................................................................................................21258
Inspection and Repair for Bearing...............................................................................................21259
Inspection and Repair for Crankshaft............................................................................................21260
Reassembly......................................................................................................................21261
Piston and Connecting Rod...........................................................................................................21264
Piston, Connecting Rod and Associate Parts......................................................................................21264
Disassembly.....................................................................................................................21264
Inspection and Repair...........................................................................................................21265
Reassembly......................................................................................................................21267
Cylinder Block......................................................................................................................21269
Cylinder Block and Associated Parts.............................................................................................21269
Disassembly.....................................................................................................................21269
Inspection and Repair...........................................................................................................21270
Reassembly......................................................................................................................21270
Balance Unit Assembly...............................................................................................................21272
Balance Unit Assembly and Associated Parts......................................................................................21272
Disassembly.....................................................................................................................21272
Adjustment......................................................................................................................21273
Reassembly......................................................................................................................21275
Main Data and Specifications........................................................................................................21276
Special Tools.......................................................................................................................21282
6B ENGINE COOLING.......................................................................................................................21283
Service Precaution..................................................................................................................21283
General Description.................................................................................................................21284
Diagnosis...........................................................................................................................21286
Draining and Refilling Cooling......................................................................................................21286
Water Pump..........................................................................................................................21287
Water Pump and Associated Parts.................................................................................................21287
Removal.........................................................................................................................21287
Inspection......................................................................................................................21287
Installation....................................................................................................................21287
Thermostat..........................................................................................................................21288
Removal.........................................................................................................................21288
Inspection......................................................................................................................21288
Installation....................................................................................................................21288
Radiator............................................................................................................................21289
Radiator and Associated Parts...................................................................................................21289
Removal.........................................................................................................................21290
Inspection......................................................................................................................21291
Installation....................................................................................................................21292
Main Data and Specifications........................................................................................................21293
Special Tool........................................................................................................................21294
6C ENGINE FUEL (Y22SE 2.2L) For Long Wheel Base.........................................................................................21295
Service Precaution..................................................................................................................21295
General Description.............................................................................................................21296
Fuel Metering...................................................................................................................21297
Fuel Filter.........................................................................................................................21298
Fuel Filter and Associated Parts................................................................................................21298
Removal.........................................................................................................................21298
Inspection......................................................................................................................21299
Installation....................................................................................................................21299
Inspection......................................................................................................................21299
In–Tank Fuel Filter.............................................................................................................21299
Fuel Pump Flow Test.............................................................................................................21299
Fuel Pump...........................................................................................................................21300
Fuel Pump and Associated Parts..................................................................................................21300
Removal.........................................................................................................................21300
Installation....................................................................................................................21301
Fuel Tube / Quick – Connector Fittings..............................................................................................21301
Precautions.....................................................................................................................21301
Cautions During Work............................................................................................................21301
Removal.........................................................................................................................21301
Reuse of Quick–Connector........................................................................................................21302
Assembling Advice...............................................................................................................21302
Fuel Pump Relay.....................................................................................................................21302
General Description.............................................................................................................21302
Fuel Tank...........................................................................................................................21303
Fuel Tank and Associated Parts..................................................................................................21303
Removal.........................................................................................................................21303
Installation....................................................................................................................21303
Fuel Gage Unit......................................................................................................................21304
Removal and Installation........................................................................................................21304
Fuel Filler Cap.....................................................................................................................21304
General Description.............................................................................................................21304
Inspection......................................................................................................................21304
Main Data and Specifications........................................................................................................21305
Special Tool....................................................................................................................21305
6D1 ENGINE ELECTRICAL...................................................................................................................21306
Service Precaution..................................................................................................................21306
Battery.............................................................................................................................21307
General Description.................................................................................................................21307
Diagnosis...........................................................................................................................21307
Battery Charging................................................................................................................21308
Jump Starting...................................................................................................................21308
Battery Removal.................................................................................................................21309
Battery Installation............................................................................................................21309
Main Data and Specifications....................................................................................................21310
6D2 IGNITION SYSTEM.....................................................................................................................21311
Service Precaution..................................................................................................................21311
General Description.................................................................................................................21312
Diagnosis...........................................................................................................................21312
Ignition Module.....................................................................................................................21313
Removal.........................................................................................................................21313
Installation....................................................................................................................21313
Spark Plug..........................................................................................................................21314
Removal.........................................................................................................................21314
Inspection and Repair...........................................................................................................21314
Installation....................................................................................................................21314
Crankshaft Position Sensor..........................................................................................................21315
Removal.........................................................................................................................21315
Installation....................................................................................................................21315
Main Data and Specifications........................................................................................................21316
6D3 STARTING AND CHARGING SYSTEM........................................................................................................21317
Service Precaution..................................................................................................................21317
Starting System.....................................................................................................................21318
General Description.................................................................................................................21318
Diagnosis...........................................................................................................................21318
Starter.............................................................................................................................21319
Removal.........................................................................................................................21319
Installation....................................................................................................................21319
Disassembled View...............................................................................................................21320
Inspection and Repair...........................................................................................................21321
Characteristic Test.............................................................................................................21322
Charging System.....................................................................................................................21323
General Description.............................................................................................................21323
General On–Vehicle Inspection...................................................................................................21323
Generator...........................................................................................................................21324
Removal.........................................................................................................................21324
Inspection......................................................................................................................21324
Installation....................................................................................................................21325
Disassembled View...............................................................................................................21326
Disassembly.....................................................................................................................21327
Inspection and Repair...........................................................................................................21328
Reassembly......................................................................................................................21329
Main Data and Specifications....................................................................................................21330
6E1 RODEO 2.2L ENGINE DRIVEABILITY AND EMISSIONS........................................................................................21331
SPECIFICATIONS......................................................................................................................21336
DIAGRAMS AND SCHEMATICS.............................................................................................................21337
PCM PINOUTS.........................................................................................................................21350
COMPONENT LOCATOR...............................................................................................................21356
Undercarriage Component Locator Table...........................................................................................21358
Fuse And Relay Panel (Underhood Electrical Center)..............................................................................21359
DIAGNOSIS Strategy-Based Diagnostics................................................................................................21360
Strategy-Based Diagnostics......................................................................................................21360
DTC Stored......................................................................................................................21360
No DTC..........................................................................................................................21360
No Matching Symptom.............................................................................................................21360
Intermittents...................................................................................................................21360
No Trouble Found................................................................................................................21360
Verifying Vehicle Repair........................................................................................................21360
GENERAL SERVICE INFORMATION.........................................................................................................21361
OBD II Serviceability Issues....................................................................................................21361
Emissions Control Information Label.............................................................................................21361
Maintenance Schedule............................................................................................................21362
Visual/Physical Engine Compartment Inspection...................................................................................21362
Basic Knowledge Of Tools Required...............................................................................................21362
SERIAL DATA COMMUNICATIONS..........................................................................................................21362
Class II Serial Data Communications.............................................................................................21362
ON-BOARDDIAGNOSTIC (OBD II).........................................................................................................21362
O-Board Diagnostic Tests........................................................................................................21362
Comprehensive Component Monitor Diagnostic Operation............................................................................21362
System Status And Drive Cycle For Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...............................21363
Common OBD II Terms.............................................................................................................21363
The Diagnostic Executive........................................................................................................21364
DTC Types.......................................................................................................................21365
Decimal/Binary/Hexadecimal Conversions..........................................................................................21366
Verifying Vehicle Repair........................................................................................................21366
Reading Diagnostic Trouble Codes Using A Tech 2 Scan Tool.......................................................................21366
Tech 2 Features.................................................................................................................21368
Getting Started.................................................................................................................21368
Operating Procedure (Example)...................................................................................................21369
DTC Modes.......................................................................................................................21370
DTC Information Mode............................................................................................................21370
Miscellaneous Test..............................................................................................................21371
Lamps Test......................................................................................................................21371
Relays Test.....................................................................................................................21372
EVAP Test.......................................................................................................................21374
Idle Air Control System Test....................................................................................................21375
Fuel System Test................................................................................................................21377
EGR Control Test................................................................................................................21378
Injector Balance Test...........................................................................................................21379
Plotting Snapshot Graph.............................................................................................................21380
System Check at Tech 2..............................................................................................................21381
General Description.............................................................................................................21381
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)..................................................21385
Flow Chart for Snapshot Replay (Plotting Graph).................................................................................21386
PRIMARY SYSTE-BASED DIAGNOSTICS.....................................................................................................21387
Primary System-Based Diagnostics................................................................................................21387
Fuel Control Heated Oxygen Sensors..............................................................................................21387
HO2S Heater.....................................................................................................................21387
Catalyst Monitor Heated Oxygen Sensors And Diagnostic Operation.................................................................21387
MISFIRE MONITOR following conditions: DIAGNOSTIC OPERATION..........................................................................21388
Misfire Monitor Diagnostic Operation............................................................................................21388
Misfire Counters................................................................................................................21388
FUEL TRIM SYSTEM MONITOR DIAGNOSTIC OPERATION.......................................................................................21389
Fuel Trim System Monitor Diagnostic Operation...................................................................................21389
Fuel Trim Cell Diagnostic Weights...............................................................................................21389
ON‐BOARD DIAGNOSTIC (OBD II) SYSTEM CHECK...........................................................................................21390
A/C CLUTCH CONTROL CIRCUIT DIAGNOSIS................................................................................................21393
ELECTRONIC IGNITION SYSTEM DIAGNOSIS................................................................................................21396
EVAP CANISTER PURGE SOLENOID........................................................................................................21396
VISUAL CHECK OF THE EVAPORATIVE EMISSION CANISTER...................................................................................21396
IDLE AIR CONTROL (IAC) VALVE........................................................................................................21396
FUEL SYSTEM PRESSURE TEST...........................................................................................................21396
FUEL METERING SYSTEM CHECK..........................................................................................................21397
FUEL INJECTOR COIL TEST PROCEDURE AND FUEL INJECTOR BALANCE TEST PROCEDURE..........................................................21397
POWERTRAIN CONTROL MODULE (PCM) DIAGNOSIS...........................................................................................21402
MULTIPLE PCM INFORMATION SENSOR DTCs SET............................................................................................21403
EXHAUST GAS RECIRCULATION (EGR) DIAGNOSIS...........................................................................................21406
ENGINE Tech 2 DATA DEFINITIONS AND RANGES...........................................................................................21406
TYPICAL SCAN DATA VALUES............................................................................................................21409
NO MALFUNCTION INDICATOR LAMP (MIL).................................................................................................21413
MALFUNCTION INDICATOR LAMP (MIL) ON STEADY..........................................................................................21416
ENGINE CRANKS BUT WILL NOT RUN......................................................................................................21418
FUEL SYSTEM ELECTRICAL TEST.........................................................................................................21424
FUEL SYSTEM DIAGNOSIS...............................................................................................................21427
IDLE AIR CONTROL (IAC) SYSTEM CHECK.................................................................................................21432
EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK........................................................................................21435
MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK.......................................................................................21437
EVAPORATIVE (EVAP) EMISSIONS CANISTER PURGE VALVE SOLENOID CHECK....................................................................21439
Upshift Lamp System Check (Manual Transmission Only)................................................................................21442
PCM DIAGNOSTIC TROUBLE CODES........................................................................................................21445
(DTC) P0106 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT/RANGE PERFORMANCE PROBLEM......................................................21448
(DTC) P0107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT LOW INPUT...............................................................21451
(DTC) P0108 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT HIGH INPUT.....................................................................21454
(DTC) P0112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW INPUT...................................................................21457
(DTC) P0113 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH INPUT..................................................................21460
(DTC) P0117 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT LOW INPUT...............................................................21463
(DTC) P0118 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT HIGH INPUT..............................................................21466
(DTC) P0121 THROTTLE POSITION (TP) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM.........................................................21469
(DTC) P0122 THROTTLE POSITION (TP) SENSOR CIRCUITLOW INPUT..........................................................................21472
(DTC) P0123 THROTTLE POSITION (TP) SENSOR CIRCUIT HIGH INPUT........................................................................21475
(DTC) P0125 INSUFFICIENT COOLANT TEM-PERATURE FOR CLOSED LOOP FUEL CONTROL..........................................................21478
(DTC) P0128 Thermostat Insufficient temperrature for Stable Opreation...............................................................21481
(DTC) P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1).........................................................................21483
(DTC) P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)........................................................................21486
(DTC) P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1).......................................................................21489
(DTC) P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)................................................................21492
(DTC) P0135 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 1)..................................................................21495
(DTC) P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2).........................................................................21498
(DTC) P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)........................................................................21501
(DTC) P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 2)................................................................21504
(DTC) P0141 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 2)..................................................................21507
(DTC) P0171 SYSTEM TOO LEAN (BANK 1)................................................................................................21510
(DTC) P0172 SYSTEM TOO RICH (BANK 1)................................................................................................21514
(DTC) P0201 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 1...............................................................................21518
(DTC) P0202 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 2...............................................................................21521
(DTC) P0203 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 3...............................................................................21524
(DTC) P0204 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 4...............................................................................21527
(DTC) P0300 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................21530
(DTC) P0301 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................21534
(DTC) P0302 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................21538
(DTC) P0303 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................21542
(DTC) P0304 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................21546
(DTC) P0325 KNOCK SENSOR (KS) CIRCUIT MALFUNCTION...................................................................................21550
(DTC) P0327 KNOCK SENSOR (KS) CIRCUIT LOW INPUT.....................................................................................21553
(DTC) P0336 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT RANGE/PERFORMANCE..............................................................21556
(DTC) P0337 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT LOW INPUT......................................................................21558
(DTC) P0341 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT RANGE/PERFORMANCE................................................................21561
(DTC) P0342 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT LOW INPUT........................................................................21564
(DTC) P0351 IGNITION COIL ”A” PRIMARY/ SECONDARY CIRCUIT MALFUNCTION................................................................21567
(DTC) P0352 IGNITION COIL ”B” PRIMARY/ SECONDARY CIRCUIT MALFUNCTION................................................................21569
(DTC) P0401 EXHAUST GAS RECIRCULATION (EGR) FLOW INSUFFICIENT DETECTED..............................................................21571
(DTC) P0402 EXHAUST GAS RECIRCULATION (EGR) EXCESSIVE FLOW DETECTED.................................................................21574
(DTC) P0404 EXHAUST GAS RECIRCULATION (EGR) CIRCUIT RANGE/PERFORMANCE...............................................................21576
(DTC) P0405 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT LOW......................................................................21580
(DTC) P0406 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT HIGH.....................................................................21583
(DTC) P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD..............................................................................21587
(DTC) P0440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM MALFUNCTION..................................................................21590
(DTC) P0442 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM SMALL LEAK DETECTED..........................................................21595
(DTC) P0456 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VERY SMALL LEAK DETECTED.....................................................21599
(DTC) P0443 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION......................................21603
(DTC) P0446 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT CONTROL CIRCUIT MALFUNCTION.............................................21606
(DTC) P0449 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT VALVE/SOLENOID CIRCUIT MALFUNCTION......................................21610
(DTC) P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE.............................................................................21613
(DTC) P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT.....................................................................................21615
(DTC) P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT....................................................................................21617
(DTC) P0464 Fuel Level Sensor Noisy Signal..........................................................................................21619
(DTC) P0480 COOLING FAN 1 CONTROL CIRCUIT MALFUNCTION...............................................................................21621
(DTC) P0481 COOLING FAN 2 CONTROL CIRCUIT MALFUNCTION...............................................................................21624
(DTC) P0502 VEHICLE SPEED SENSOR (VSS) CIRCUIT LOW INPUT............................................................................21627
(DTC) P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED.............................................................................21629
(DTC) P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED............................................................................21632
(DTC) P0532 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT LOW INPUT.......................................................................21635
(DTC) P0533 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT HIGH INPUT......................................................................21638
(DTC) P0562 SYSTEM VOLTAGE LOW......................................................................................................21641
(DTC) P0563 SYSTEM VOLTAGE HIGH.....................................................................................................21643
(DTC) P0601 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR..........................................................................21645
(DTC) P1106 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE...............................................21647
(DTC) P1107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE................................................21649
(DTC) P1111 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE...................................................21651
(DTC) P1112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE....................................................21654
(DTC) P1114 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE................................................21656
(DTC) P1115 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE...............................................21658
(DTC) P1121 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE.........................................................21661
(DTC) P1122 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE..........................................................21663
(DTC) P1133 O2 SENSOR INSUFFICIENT SWITCHING (BANK 1 SENSOR 1)......................................................................21665
(DTC) P1134 O2 SENSOR TRANSITION TIME RATIO (BANK 1 SENSOR 1).......................................................................21668
(DTC) P1171 FUEL SYSTEM LEAN DURING ACCELERATION....................................................................................21671
(DTC) P1336 CRANKSHAFT POSITION SENSOR (CKP) SYSTEM VARIATION NOT LEARNED...........................................................21674
(DTC) P1380 ABS ROUGH ROAD SYSTEM FAULT.............................................................................................21677
(DTC) P1381 ABS ROUGH ROAD CLASS 2 SERIAL DATA FAULT................................................................................21679
(DTC) P1404 EXHAUST GAS RECIRCULATION (EGR) CLOSED VALVE............................................................................21682
(DTC) P1441 EVAPORATIVE EMISSION (EVAP) SYSTEM FLOW DURING NO-PURGE.................................................................21685
(DTC) P1546 A/C COMPRESSOR CLUTCH OUTPUT CIRCUIT MALFUNCTION........................................................................21688
(DTC) P1618 Serial Peripheral Interface (SPI) PCM Interprocessor Communication Error................................................21691
(DTC) P1625 PCM Unexpected Reset....................................................................................................21692
(DTC) P1627 PCM A/D CONVERSION MALFUNCTION..........................................................................................21694
(DTC) P1635 5 VOLT REFERENCE VOLTAGE CIRCUIT MALFUNCTION............................................................................21696
SYMPTOM DIAGNOSIS...................................................................................................................21698
DEFAULT MATRIX TABLE................................................................................................................21721
Camshaft Position (CMP) Sensor......................................................................................................21724
Removal Procedure...............................................................................................................21724
Installation Procedure..........................................................................................................21724
Crankshaft Position (CKP) Sensor....................................................................................................21725
Removal Procedure...............................................................................................................21725
Installation Procedure..........................................................................................................21726
EEPROM..............................................................................................................................21727
EEPROM..........................................................................................................................21727
EEPROM Programming..............................................................................................................21727
Engine Coolant Temperature (ECT) Sensor.............................................................................................21727
Removal Procedure...............................................................................................................21727
Installation Procedure..........................................................................................................21728
Heated Oxygen Sensor (HO2S).........................................................................................................21728
Removal Procedure...............................................................................................................21728
Inspection Procedure............................................................................................................21728
Installation Procedure..........................................................................................................21729
Intake Air Temperature (IAT) Sensor.................................................................................................21729
Removal Procedure...............................................................................................................21729
Installation Procedure..........................................................................................................21730
Manifold Absolute Pressure (MAP) Sensor.............................................................................................21730
Removal Procedure...............................................................................................................21730
Installation Procedure..........................................................................................................21730
Malfunction Indicator Lamp (MIL)....................................................................................................21731
Malfunction Indicator Lamp (MIL)................................................................................................21731
Powertrain Control Module (PCM).....................................................................................................21731
Electrostatic Discharge (ESD) Damage............................................................................................21731
Removal Procedure...............................................................................................................21731
Installation Procedure..........................................................................................................21733
Throttle Position (TP) Sensor.......................................................................................................21734
Removal Procedure...............................................................................................................21734
Function Check..................................................................................................................21734
Installation Procedure..........................................................................................................21734
Vehicle Speed Sensor (VSS)..........................................................................................................21735
Removal Procedure...............................................................................................................21735
Inspection Procedure............................................................................................................21735
Installation Procedure..........................................................................................................21735
Air Filter..........................................................................................................................21736
Removal Procedure...............................................................................................................21736
Installation Procedure..........................................................................................................21736
Idle Air Control (IAC) Valve........................................................................................................21737
Removal Procedure...............................................................................................................21737
Cleaning and Inspection Procedure...............................................................................................21737
Measurement Procedure...........................................................................................................21738
Installation Procedure..........................................................................................................21738
Intake Air Duct.....................................................................................................................21738
Removal Procedure...............................................................................................................21738
Installation Procedure..........................................................................................................21739
Knock Sensor........................................................................................................................21740
Removal Procedure...............................................................................................................21740
Installation Procedure..........................................................................................................21740
Oil Pressure Switch.................................................................................................................21741
Removal Procedure...............................................................................................................21741
Installation Procedure..........................................................................................................21741
FUEL METERING SYSTEM Accelerator Cable Assembly.....................................................................................21741
Removal Procedure...............................................................................................................21741
Inspection Procedure............................................................................................................21742
Installation Procedure..........................................................................................................21742
Accelerator Cable Adjustment....................................................................................................21743
Accelerator Pedal Replacement.......................................................................................................21743
Removal Procedure...............................................................................................................21743
Installation Procedure..........................................................................................................21743
Fuel Filler Cap.....................................................................................................................21744
Fuel Filler Cap.....................................................................................................................21744
Inspection Procedure............................................................................................................21744
Fuel Filter.........................................................................................................................21744
Removal Procedure...............................................................................................................21744
Inspection Procedure............................................................................................................21745
Installation Procedure..........................................................................................................21745
Fuel Injectors......................................................................................................................21746
Removal Procedure...............................................................................................................21746
Inspection Procedure............................................................................................................21746
Installation Procedure..........................................................................................................21746
Fuel Pressure Regulator.............................................................................................................21747
Removal Procedure...............................................................................................................21747
Installation Procedure..........................................................................................................21748
Fuel Pressure Relief Procedure..................................................................................................21748
Fuel Pump Assembly..................................................................................................................21749
Removal Procedure...............................................................................................................21749
Inspection Procedure............................................................................................................21750
Installation Procedure..........................................................................................................21750
Fuel Pump Relay.....................................................................................................................21751
Removal Procedure...............................................................................................................21751
Installation Procedure..........................................................................................................21751
Fuel Rail Assembly..................................................................................................................21751
Removal Procedure...............................................................................................................21751
Installation Procedure..........................................................................................................21752
Fuel Tank...........................................................................................................................21753
Removal Procedure...............................................................................................................21753
Installation Procedure..........................................................................................................21753
Throttle body (TB)..................................................................................................................21754
Removal Procedure...............................................................................................................21754
Inspection Procedure............................................................................................................21754
Installation Procedure..........................................................................................................21755
ELECTRONIC IGNITION SYSTEM Ignition Control Module (ICM)............................................................................21756
Removal Procedure...............................................................................................................21756
Installation Procedure..........................................................................................................21756
Ignition Coil.......................................................................................................................21756
Removal Procedure...............................................................................................................21756
Installation Procedure..........................................................................................................21756
Spark Plugs.........................................................................................................................21757
Removal Procedure...............................................................................................................21757
Inspection Procedure............................................................................................................21757
Installation Procedure..........................................................................................................21758
Spark Plug Cables...................................................................................................................21758
Spark Plug Cables...................................................................................................................21758
Inspection Procedure............................................................................................................21758
EMISSIONS Catalytic Converter.......................................................................................................21759
Catalytic Converter.............................................................................................................21759
Air Conditioning Relay..............................................................................................................21759
Removal Procedure...............................................................................................................21759
Installation Procedure..........................................................................................................21759
Ignition Timing Adjustment..........................................................................................................21759
Ignition Timing Adjustment......................................................................................................21759
EVAP Canister Hoses.................................................................................................................21759
EVAP Canister Hoses.............................................................................................................21759
EVAP Canister.......................................................................................................................21759
Removal Procedure...............................................................................................................21759
Inspection Procedure............................................................................................................21759
Installation Procedure..........................................................................................................21759
EVAP Canister Vent Solenoid.........................................................................................................21760
Removal Procedure...............................................................................................................21760
Installation Procedure..........................................................................................................21760
EVAP Canister Purge Valve Solenoid..................................................................................................21760
Removal Procedure...............................................................................................................21760
Installation Procedure..........................................................................................................21761
Linear Exhaust Gas Recirculation (EGR) Valve........................................................................................21761
Removal Procedure...............................................................................................................21761
Inspection Procedure............................................................................................................21761
Installation Procedure..........................................................................................................21762
Wiring and Connectors...............................................................................................................21763
Wiring Harness Service..........................................................................................................21763
PCM Connectors And Terminals........................................................................................................21763
Removal Procedure...............................................................................................................21763
Installation Procedure..........................................................................................................21763
Connectors And Terminals............................................................................................................21763
Connectors And Terminals........................................................................................................21763
Wire Harness Repair: Twisted Shielded Cable.........................................................................................21763
Removal Procedure...............................................................................................................21763
Installation Procedure..........................................................................................................21764
Twisted Leads.......................................................................................................................21764
Removal Procedure...............................................................................................................21764
Installation Procedure..........................................................................................................21764
Weathe-Pack Connector...............................................................................................................21765
Tools Required..................................................................................................................21765
Removal Procedure...............................................................................................................21765
Installation Procedure..........................................................................................................21766
Com-Pack III........................................................................................................................21766
Com-Pack III....................................................................................................................21766
Metri-Pack..........................................................................................................................21767
Tools Required..................................................................................................................21767
Removal Procedure...............................................................................................................21767
Installation Procedure..........................................................................................................21767
GENERAL DESCRIPTION-PCM AND SENSORS.................................................................................................21767
GENERAL DESCRIPTION-AIRINDUCTION....................................................................................................21775
GENERAL DESCRIPTION-FUELMETERING....................................................................................................21775
GENERAL DESCRIPTION-ELECTRONIC IGNITION SYSTEM......................................................................................21778
A/C CLUTCH DIAGNOSIS................................................................................................................21782
GENERAL DESCRIPTION-EVAPORATIVE EMISSION (EVAP)SYSTEM...............................................................................21782
GENERAL DESCRIPTION-EXHAUST GAS RECIRCULATION(EGR) SYSTEM...........................................................................21784
GENERAL DESCRIPTION-POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM.....................................................................21785
SPECIAL TOOLS.......................................................................................................................21786
6F ENGINE EXHAUST.......................................................................................................................21788
Service Precaution..................................................................................................................21788
General Description.................................................................................................................21789
Front Exhaust Pipe..................................................................................................................21790
Front Exhaust Pipe and Associated Parts.........................................................................................21790
Removal.........................................................................................................................21790
Installation....................................................................................................................21790
Exhaust Silencer....................................................................................................................21791
Exhaust Silencer and Associated Parts...........................................................................................21791
Removal.........................................................................................................................21791
Installation....................................................................................................................21791
Rear Exhaust pipe...................................................................................................................21792
Rear Exhaust pipe and Associated Parts..........................................................................................21792
Removal.........................................................................................................................21792
Installation....................................................................................................................21792
Main Data and Specifications........................................................................................................21793
6G ENGINE LUBRICATION...................................................................................................................21794
Service Precaution..................................................................................................................21794
General Description.................................................................................................................21795
Oil Pump............................................................................................................................21796
Oil Pump and Associated Parts...................................................................................................21796
Disassembly.....................................................................................................................21797
Inspection and Repair...........................................................................................................21797
Reassembly......................................................................................................................21797
6H ENGINE SPEED CONTROL SYSTEM..........................................................................................................21798
Service Precaution..................................................................................................................21798
Accelerator Pedal Control Cable.....................................................................................................21799
Removal.........................................................................................................................21799
Inspection......................................................................................................................21799
Installation....................................................................................................................21799
Adjustment......................................................................................................................21799
Accelerator Pedal...................................................................................................................21800
Accelerator Pedal and Associated Parts..........................................................................................21800
Removal.........................................................................................................................21800
Installation....................................................................................................................21800
6J INDUCTION............................................................................................................................21801
Service Precaution..................................................................................................................21801
Air Cleaner Filter..................................................................................................................21802
Removal.........................................................................................................................21802
Inspection......................................................................................................................21802
Installation....................................................................................................................21802
6VD1 3.2L ENGINE..........................................................................................................................21803
6A ENGINE MECHANICAL....................................................................................................................21803
Service Precaution..................................................................................................................21804
General Description.................................................................................................................21805
Engine Diagnosis....................................................................................................................21806
Cylinder Head Cover LH..............................................................................................................21821
Removal.........................................................................................................................21821
Installation....................................................................................................................21822
Cylinder Head Cover RH..............................................................................................................21823
Removal.........................................................................................................................21823
Installation....................................................................................................................21823
Common Chamber......................................................................................................................21824
Removal.........................................................................................................................21824
Installation....................................................................................................................21824
Exhaust Manifold LH.................................................................................................................21826
Removal.........................................................................................................................21826
Installation....................................................................................................................21826
Exhaust Manifold RH.................................................................................................................21827
Removal.........................................................................................................................21827
Installation....................................................................................................................21827
Crankshaft Pulley...................................................................................................................21828
Removal.........................................................................................................................21828
Installation....................................................................................................................21828
Timing Belt.........................................................................................................................21829
Removal.........................................................................................................................21829
Installation....................................................................................................................21830
Camshaft............................................................................................................................21833
Removal.........................................................................................................................21833
Installation....................................................................................................................21834
Cylinder Head.......................................................................................................................21836
Removal.........................................................................................................................21836
Installation....................................................................................................................21836
Valve Stem Oil Controller , Valve Spring and Valve Guide............................................................................21838
Removal.........................................................................................................................21838
Installation....................................................................................................................21838
Piston, Piston Ring and Connecting Rod..............................................................................................21839
Removal.........................................................................................................................21839
Installation....................................................................................................................21840
Crankshaft and Main Bearings........................................................................................................21841
Removal.........................................................................................................................21841
Installation....................................................................................................................21842
Rear Oil Seal.......................................................................................................................21846
Removal.........................................................................................................................21846
Installation....................................................................................................................21846
Engine Assembly.....................................................................................................................21847
Removal.........................................................................................................................21847
Installation....................................................................................................................21848
Cylinder Head.......................................................................................................................21850
Cylinder Head and Associated Parts..............................................................................................21850
Disassembly.....................................................................................................................21850
Clean...........................................................................................................................21851
Inspection and Repair...........................................................................................................21851
Reassembly......................................................................................................................21852
Valve Spring, Oil Controller, Valve, Valve Guide....................................................................................21854
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts...........................................................21854
Disassembly.....................................................................................................................21854
Inspection and Repair...........................................................................................................21855
Reassembly......................................................................................................................21858
Camshaft............................................................................................................................21861
Camshaft and Associated Parts...................................................................................................21861
Disassembly.....................................................................................................................21861
Inspection and Repair...........................................................................................................21862
Reassembly......................................................................................................................21864
Crankshaft..........................................................................................................................21867
Crankshaft and Associated Parts.................................................................................................21867
Disassembly.....................................................................................................................21867
Inspection and Repair for Bearings..............................................................................................21868
Inspection and Repair for Crankshaft............................................................................................21870
Reassembly......................................................................................................................21871
Piston and Connecting Rod...........................................................................................................21875
Piston, Connecting Rod and Associate Parts......................................................................................21875
Disassembly.....................................................................................................................21875
Inspection and Repair...........................................................................................................21876
Reassembly......................................................................................................................21880
Cylinder Block......................................................................................................................21882
Cylinder Block and Associated Parts.............................................................................................21882
Disassembly.....................................................................................................................21882
Inspection and Repair...........................................................................................................21883
Reassembly......................................................................................................................21884
Main Data and Specification.........................................................................................................21887
Special Tool........................................................................................................................21893
6B ENGINE COOLING.......................................................................................................................21895
Service Precaution..................................................................................................................21895
General Description.................................................................................................................21896
Diagnosis...........................................................................................................................21898
Draining and Refilling Cooling System...............................................................................................21899
Water Pump..........................................................................................................................21900
Water Pump and Associated Parts.................................................................................................21900
Removal.........................................................................................................................21900
Inspection......................................................................................................................21900
Installation....................................................................................................................21900
Thermostat..........................................................................................................................21901
Thermostat and Associated Parts.................................................................................................21901
Removal.........................................................................................................................21901
Inspection......................................................................................................................21901
Installation....................................................................................................................21901
Radiator............................................................................................................................21902
Radiator and Associated Parts...................................................................................................21902
Removal.........................................................................................................................21902
Inspection......................................................................................................................21903
Installation....................................................................................................................21904
Drive Belt and Cooling Fan..........................................................................................................21905
Drive Belt and Associated Parts.................................................................................................21905
Removal.........................................................................................................................21905
Inspection......................................................................................................................21905
Installation....................................................................................................................21905
Main Data and Specifications........................................................................................................21906
Special Tool........................................................................................................................21907
6C ENGINE FUEL FOR LONG WHEEL BASE......................................................................................................21908
Service Precaution..................................................................................................................21908
General Description.............................................................................................................21909
Fuel Metering...................................................................................................................21910
Fuel Filter.........................................................................................................................21911
Removal.........................................................................................................................21911
Inspection......................................................................................................................21911
Installation....................................................................................................................21912
Inspection......................................................................................................................21912
In–Tank Fuel Filter.............................................................................................................21912
Fuel Pump Flow Test.............................................................................................................21912
Fuel Pump...........................................................................................................................21913
Fuel Pump and Associated Parts..................................................................................................21913
Removal.........................................................................................................................21913
Installation....................................................................................................................21914
Fuel Tube / Quick – Connector Fittings..............................................................................................21914
Precautions.....................................................................................................................21914
Cautions During Work............................................................................................................21914
Removal.........................................................................................................................21914
Reuse of Quick–Connector........................................................................................................21915
Assembling Advice...............................................................................................................21915
Fuel Pump Relay.....................................................................................................................21916
General Description.............................................................................................................21916
Fuel Tank...........................................................................................................................21916
Fuel Tank and Associated Parts..................................................................................................21916
Removal.........................................................................................................................21916
Installation....................................................................................................................21917
Fuel Gauge Unit.....................................................................................................................21917
Removal and Installation........................................................................................................21917
Fuel Filler Cap.....................................................................................................................21917
General Description.............................................................................................................21917
Inspection......................................................................................................................21917
Main Data and Specifications........................................................................................................21918
Special Tool....................................................................................................................21918
6D1 ENGINE ELECTRICAL...................................................................................................................21919
Service Precaution..................................................................................................................21919
Battery.............................................................................................................................21920
General Description.................................................................................................................21920
Diagnosis...........................................................................................................................21920
Battery Charging....................................................................................................................21921
Jump Starting.......................................................................................................................21921
Battery Removal.....................................................................................................................21922
Battery Installation................................................................................................................21922
Main Data and Specifications........................................................................................................21923
6D2 IGNITION SYSTEM.....................................................................................................................21924
Service Precaution..................................................................................................................21924
General Description.................................................................................................................21925
Diagnosis...........................................................................................................................21925
Ignition Coil.......................................................................................................................21926
Removal.........................................................................................................................21926
Inspection and Repair...........................................................................................................21926
Installation....................................................................................................................21926
Spark Plug..........................................................................................................................21928
Removal.........................................................................................................................21928
Inspection and Repair...........................................................................................................21928
Installation....................................................................................................................21928
Crankshaft Position Sensor..........................................................................................................21929
Removal.........................................................................................................................21929
Installation....................................................................................................................21929
Main Data and Specifications........................................................................................................21930
6D3 STARTING AND CHARGING SYSTEM (6VD1 3.2L)............................................................................................21931
Service Precaution..................................................................................................................21931
Starting System.....................................................................................................................21932
General Description.............................................................................................................21932
Diagnosis.......................................................................................................................21934
Starter.............................................................................................................................21935
Removal.........................................................................................................................21935
Installation....................................................................................................................21935
Disassembled View...............................................................................................................21937
Disassembly.....................................................................................................................21938
Inspection and Repair...........................................................................................................21940
Reassembly......................................................................................................................21943
Main Data and Specifications........................................................................................................21944
Charging System.....................................................................................................................21947
General Description.............................................................................................................21947
General On–Vehicle Inspection...................................................................................................21947
Generator...........................................................................................................................21948
Removal.........................................................................................................................21948
Inspection......................................................................................................................21948
Installation....................................................................................................................21949
Disassembled View...............................................................................................................21949
Disassembly.....................................................................................................................21950
Inspection and Repair...........................................................................................................21951
Reassembly......................................................................................................................21953
Bench Test......................................................................................................................21954
Main Data and Specifications........................................................................................................21955
6E2 DRIVEABILITY AND EMISSIONS..........................................................................................................21956
Specifications......................................................................................................................21961
Tightening Specifications.......................................................................................................21961
Diagrams and Schematics.............................................................................................................21962
PCM Wiring Diagram (1 of 7).....................................................................................................21962
PCM Wiring Diagram (2 of 7).....................................................................................................21963
PCM Wiring Diagram (3 of 7).....................................................................................................21964
PCM Wiring Diagram (4 of 7).....................................................................................................21965
PCM Wiring Diagram (5 of 7).....................................................................................................21966
PCM Wiring Diagram (6 of 7).....................................................................................................21967
PCM Wiring Diagram (7 of 7).....................................................................................................21968
PCM Pinouts.........................................................................................................................21969
PCM Pinout Table, 80-Way Blue Connector - Row "F1～20"...........................................................................21969
PCM Pinout Table, 80-Way Blue Connector - Row "F20～40"..........................................................................21970
PCM Pinout Table, 80-Way Blue Connector - Row "F41～60"..........................................................................21971
PCM Pinout Table, 80-Way Blue Connector - Row "F61～80"..........................................................................21972
PCM Pinout Table, 80-Way Red Connector - Row "S1～20"............................................................................21974
PCM Pinout Table, 80-Way Red Connector - Row "S21～40"...........................................................................21976
PCM Pinout Table, 80-Way Red Connector - Row "S41～60"...........................................................................21978
PCM Pinout Table, 80-Way Red Connector - Row "S61～80"...........................................................................21980
Component Locators..............................................................................................................21982
Undercarriage Component Locator.................................................................................................21984
Fuse and Relay Panel (Underhood Electrical Center)..............................................................................21985
Sensors and Miscellaneous Component Locators....................................................................................21986
Diagnosis...........................................................................................................................21988
Strategy-Based Diagnostics......................................................................................................21988
DTC Stored......................................................................................................................21988
No DTC..........................................................................................................................21988
No Matching Symptom.............................................................................................................21988
Intermittents...................................................................................................................21988
No Trouble Found................................................................................................................21988
Verifying Vehicle Repair........................................................................................................21988
General Service Information.........................................................................................................21988
OBD II Serviceablity Issues.....................................................................................................21988
Emissions Control Information Label.............................................................................................21989
Visual / Physical Engine Compartment Inspection.................................................................................21989
Basic Knowledge of Tools Required...............................................................................................21990
Serial Data Communications..........................................................................................................21990
Class 2 Serial Data Communications..............................................................................................21990
On-Board Diagnostic (OBD II)........................................................................................................21990
On-Board Diagnostic Tests.......................................................................................................21990
Comprehensive Component Monitor Diagnostic Operation............................................................................21990
System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...............................21991
Common OBD II Terms.............................................................................................................21991
The Diagnostic Executive........................................................................................................21991
DTC Types.......................................................................................................................21992
Decimal/Binary/Hexadecimal Conversions..........................................................................................21994
Verifying Vehicle Repair........................................................................................................21994
Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool.....................................................................21994
Tech 2..........................................................................................................................21995
Tech 2 Features.................................................................................................................21996
Getting Started.................................................................................................................21996
Operating Procedure (For Example)...............................................................................................21997
DTC Modes.......................................................................................................................21998
DTC Information Mode............................................................................................................21998
Miscellaneous Test..............................................................................................................21999
Lamps Test......................................................................................................................21999
Relays Test.....................................................................................................................22001
EVAP Test.......................................................................................................................22002
Fuel System Test................................................................................................................22003
Instruments Test................................................................................................................22005
EGR Control Test................................................................................................................22007
Injector Balance Test...........................................................................................................22009
Plotting Snapshot Graph.............................................................................................................22009
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)..................................................22010
Flow Chart for Snapshot Replay (Plotting Graph).................................................................................22011
Primary System-Based Diagnostic.....................................................................................................22012
Primary System-Based Diagnostic.................................................................................................22012
Fuel Control Heated Oxygen Sensor...............................................................................................22012
HO2S Heater.....................................................................................................................22012
Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation.................................................................22012
Misfire Monitor Diagnostic Operation................................................................................................22013
Misfire Monitor Diagnostic Operation............................................................................................22013
Misfire Counters................................................................................................................22013
Fuel Trim System Monitor Diagnostic Operation.......................................................................................22014
Fuel Trim System Monitor Diagnostic Operation...................................................................................22014
Fuel Trim Cell Diagnostic Weights...............................................................................................22014
On-Board Diagnostic (OBD II) System Check...........................................................................................22015
Circuit Description.............................................................................................................22015
Diagnostic Aids.................................................................................................................22015
Test Description................................................................................................................22015
A/C Clutch Control Circuit Diagnosis................................................................................................22018
Circuit Description.............................................................................................................22018
Diagnostic Aids.................................................................................................................22018
A/C Clutch Diagnosis............................................................................................................22019
Test Description................................................................................................................22019
Electronic Ignition System Diagnosis................................................................................................22023
EVAP Canister Purge Solenoid and EVAP Vent Solenoid Valve...........................................................................22023
Visual Check of The Evaporative Emission Canister...................................................................................22023
Fuel Metering System Check..........................................................................................................22023
Fuel System Pressure Test...........................................................................................................22023
Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure..........................................................22023
Test Description................................................................................................................22023
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11).......................................22024
Powertrain Control Module (PCM) Diagnosis...........................................................................................22028
Multiple PCM Information Sensor DTCs Set............................................................................................22028
Circuit Description.............................................................................................................22028
Diagnostic Aids.................................................................................................................22028
Exhaust Gas Recirculation (EGR) Diagnosis...........................................................................................22031
Engine Tech 2 Data Definitions and Ranges...........................................................................................22031
Typical Scan Data Values............................................................................................................22033
Test Conditions.................................................................................................................22033
No Malfunction Indicator Lamp (MIL).................................................................................................22039
Circuit Description.............................................................................................................22039
Diagnostic Aids.................................................................................................................22039
Test Description................................................................................................................22039
Malfunction Indicator Lamp (MIL) "ON" Steady........................................................................................22042
Circuit description.............................................................................................................22042
Diagnostic Aids.................................................................................................................22042
Test Description................................................................................................................22042
No Reduced Power Lamp (RPL).........................................................................................................22044
Circuit Description.............................................................................................................22044
Diagnostic Aids.................................................................................................................22044
Test Description................................................................................................................22044
Reduced Power Lamp (RPL) "ON" Steady................................................................................................22048
Circuit Description.............................................................................................................22048
Diagnostic Aids.................................................................................................................22048
Test Description................................................................................................................22048
Starter Control System Check........................................................................................................22051
Circuit Description.............................................................................................................22051
Diagnostic Aids.................................................................................................................22051
Test Description................................................................................................................22051
Engine Cranks But Will Not Run......................................................................................................22055
Circuit Description.............................................................................................................22057
Diagnostic Aids.................................................................................................................22057
Test Description................................................................................................................22057
Fuel System Electrical Test.........................................................................................................22062
Circuit Description.............................................................................................................22063
Diagnostic Aids.................................................................................................................22063
Test Description................................................................................................................22063
Fuel Pressure Relief Procedure..................................................................................................22063
Fuel Gauge Installation.........................................................................................................22063
Electric Throttle Control (ETC) System Check........................................................................................22066
Circuit Description.............................................................................................................22067
Diagnostic Aids.................................................................................................................22067
Test Description................................................................................................................22067
Fuel System Diagnosis...............................................................................................................22070
Circuit Description.............................................................................................................22071
Test Description................................................................................................................22071
Fuel Pressure Relief Procedure..................................................................................................22072
Fuel Gauge Installation.........................................................................................................22072
Exhaust Gas Recirculation (EGR) System Check........................................................................................22075
Circuit Description.............................................................................................................22075
Diagnostic Aids.................................................................................................................22075
Manifold Absolute Pressure (MAP) Output Check.......................................................................................22077
Circuit Description.............................................................................................................22077
Test Description................................................................................................................22077
Evaporative (EVAP) Emissions Canister Purge Valve Check.............................................................................22079
Circuit Description.............................................................................................................22079
Diagnostic Aids.................................................................................................................22079
Test Description................................................................................................................22079
PCM Diagnostic Trouble Codes........................................................................................................22082
Diagnostic Trouble Code (DTC) P0101 MAF System Performance..........................................................................22086
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency................................................................22089
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency...............................................................22092
Diagnostic Trouble Code (DTC) P0106 MAP System Performance..........................................................................22095
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage..................................................................22098
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage.................................................................22101
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage..................................................................22104
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage.................................................................22107
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage..................................................................22110
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage.................................................................22113
Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control..................................................22116
Diagnostic Trouble Code(DTC) P0128 Thermostat Insufficient Temperature for Stable Operation.........................................22119
Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1........................................................22121
Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1.......................................................22124
Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1..............................................................22127
Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1..............................................22131
Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1.............................................................22134
Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2........................................................22137
Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2.......................................................22140
Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2...............................................22143
Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2.............................................................22146
Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1........................................................22149
Diagnostic Trouble Code (DTC) P0152 HO2S Circuit High Voltage Bank 2 Sensor 1.......................................................22152
Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1..............................................................22155
Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1..............................................22159
Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Open Bank 2 Sensor 1........................................................22162
Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2........................................................22165
Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2.......................................................22168
Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2..............................................22171
Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2.............................................................22174
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1....................................................................22177
Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1....................................................................22181
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2....................................................................22185
Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2....................................................................22189
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit......................................................................22193
Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit......................................................................22196
Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit......................................................................22199
Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit......................................................................22202
Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit......................................................................22205
Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit......................................................................22208
Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected.........................................................................22211
Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected.......................................................................22215
Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected.......................................................................22217
Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected.......................................................................22219
Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected.......................................................................22221
Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected.......................................................................22223
Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected.......................................................................22225
Diagnostic Trouble Code (DTC) P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault....................................22227
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit....................................................................22230
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency................................................................22233
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit......................................................................22236
Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit......................................................................22239
Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit......................................................................22242
Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit......................................................................22245
Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit......................................................................22248
Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit......................................................................22251
Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient...........................................................................22254
Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error..........................................................................22257
Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck..................................................................................22259
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage.................................................................................22261
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage................................................................................22264
Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1................................................................22267
Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2................................................................22270
Diagnostic Trouble Code (DTC) P0440 EVAP System.....................................................................................22273
Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected.................................................................22276
Diagnostic Trouble Code (DTC) P0444 EVAP Purge Control Circuit Open.................................................................22279
Diagnostic Trouble Code (DTC) P0445 EVAP Purge Control Circuit Short................................................................22281
Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Control Malfunction..........................................................22283
Diagnostic Trouble Code (DTC) P0447 EVAP Vent Solenoid Circuit Open.................................................................22286
Diagnostic Trouble Code (DTC) P0448 EVAP Vent solenoid Circuit Short................................................................22288
Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) Low Voltage...................................22290
Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) High Voltage..................................22293
Diagnostic Trouble Code (DTC) P0456 EVAP Very Small Leak............................................................................22296
Diagnostic Trouble Code (DTC) P0461 Fuel Level Sensor Performance...................................................................22299
Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit-Low Voltage...........................................................22301
Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit-High Voltage..........................................................22304
Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Noisy Signal..................................................................22306
Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input...........................................................................22308
Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM.................................................................22311
Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM................................................................22314
Diagnostic Trouble Code (DTC) P0562 System Voltage Low..............................................................................22317
Diagnostic Trouble Code (DTC) P0563 System Voltage High.............................................................................22319
Diagnostic Trouble Code (DTC) P0565 Cruise Main Switch Circuit Error................................................................22321
Diagnostic Trouble Code (DTC) P0566 Cruise Cancel Switch Circuit Error..............................................................22323
Diagnostic Trouble Code (DTC) P0567 Cruise Resume Switch Circuit Error..............................................................22325
Diagnostic Trouble Code (DTC) P0568 Cruise Set Switch Circuit Error.................................................................22327
Diagnostic Trouble Code (DTC) P0571 No Brake Switch Signal..........................................................................22329
Diagnostic Trouble Code (DTC) P0601 PCM Memory......................................................................................22331
Diagnostic Trouble Code (DTC) P0602 PCM Programming Error...........................................................................22333
Diagnostic Trouble Code (DTC) P0604 PCM RAM Error...................................................................................22335
Diagnostic Trouble Code (DTC) P0606 PCM Internal Performance........................................................................22337
Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage....................................................22339
Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage............................................................22341
Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage....................................................22343
Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage.....................................................22346
Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage.....................................................22348
Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage....................................................22350
Diagnostic Trouble Code(DTC) P1120-TPS 1 Throttle Position Sensor (TPS1) Circuit Fault..............................................22353
Diagnostic Trouble Code (DTC) P1125 ETC (Electric throttle control) Limit Performance Mode..........................................22356
Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1.....................................................22359
Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1......................................................22363
Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1.....................................................22367
Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1..............................................22371
Diagnostic Trouble Code (DTC) P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1).............................................22375
Diagnostic Trouble Code (DTC) P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2).............................................22377
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration............................................................22379
Diagnostic Trouble Code (DTC) P1220 Throttle Position Senser2 (TPS2) Circuit Fault..................................................22382
Diagnosis Truble Code(DTC) P1221 TPS1 - TPS2 correlation(Circuit Performance).......................................................22385
Diagnostic Trouble Code (DTC) P1271 APS 1・2 Correlation Error.......................................................................22388
Diagnostic Trouble Code (DTC) P1272 APS 2 - 3 Correlation Error.....................................................................22391
Diagnostic Trouble Code (DTC) P1273 APS 1 - 3 Correlation Error.....................................................................22394
Diagnostic Trouble Code (DTC) P1275 APS 1 Circuit Fault.............................................................................22397
Diagnostic Trouble Code (DTC) P1280 APS 2 Circuit Fault.............................................................................22399
Diagnostic Trouble Code (DTC) P1285 APS 3 Circuit Fault.............................................................................22401
Diagnostic Trouble Code (DTC) P1290 ETC Forced Idle Mode............................................................................22403
Diagnostic Trouble Code (DTC) P1295 Power Management Mode...........................................................................22405
Diagnostic Trouble Code (DTC) P1299 ETC Forced Engine Shutdown Mode.................................................................22407
Diagnostic Trouble Code (DTC) P1310 ION Sensing Module Diagnosis....................................................................22409
Diagnostic Trouble Code (DTC) P1311 ION Sensing Module SEC Line 1 Circuit Fault.....................................................22412
Diagnostic Trouble Code (DTC) P1312 ION Sensing Module SEC Line 2 Circuit Fault.....................................................22415
Diagnostic Trouble Code (DTC) P1326 ION Sensing Module Combustion Quality Input Circuit Fault.......................................22418
Diagnostic Trouble Code (DTC) P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)............................22421
Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed................................................................................22424
Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge...............................................................22427
Diagnostic Trouble Code (DTC) P1514 TPS - MAF Correlation Error.....................................................................22430
Diagnostic Trouble Code (DTC) P1515 Command - Actual TPS Correlation Error..........................................................22434
Diagnostic Trouble Code (DTC) P1516 Command - Actual TPS Correlation Error..........................................................22437
Diagnostic Trouble Code (DTC) P1523 Actuator Control Return Performance.............................................................22440
Diagnostic Trouble Code (DTC) P1571 Brake Switch No Operation.......................................................................22443
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset............................................................................22445
Diagnostic Trouble Code (DTC) P1635 Reference Voltage # 1 Circuit Fault.............................................................22446
Diagnostic Trouble Code (DTC) P1639 Reference Voltage # 2 Circuit Fault.............................................................22448
Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM).............................................................22450
Diagnostic Trouble Code (DTC) P1650 Quad Driver Module "A" Fault....................................................................22452
Symptom Diagnosis...................................................................................................................22455
Default Matrix Table................................................................................................................22484
Default Matrix Table............................................................................................................22484
On Vehicle Service Crankshaft Position (CKP) Sensor.............................................................................22487
Engine Coolant Temperature (ECT) Sensor.............................................................................................22487
Heated Oxygen Sensor (HO2S).........................................................................................................22488
Intake Air Temperature (IAT) Sensor.................................................................................................22491
ION Sensing Module..................................................................................................................22491
Mass Air Flow (MAF) Sensor..........................................................................................................22492
Manifold Absolute Pressure (MAP) Sensor.............................................................................................22493
Malfunction Indicator Lamp (MIL)....................................................................................................22494
Reduced Power Lamp..................................................................................................................22494
Powertrain Control Module (PCM).....................................................................................................22494
EEPROM..............................................................................................................................22496
Throttle Position (TP) Sensor.......................................................................................................22496
Vehicle Speed Sensor (VSS)..........................................................................................................22497
Air Cleaner/Air Filter..............................................................................................................22498
Common Chamber......................................................................................................................22498
Accelerator Pedal Replacement.......................................................................................................22499
Accelerator Position Sensor Replacement.............................................................................................22500
Accelerator Position Sensor Adjustment..............................................................................................22500
Fuel Filler Cap.....................................................................................................................22501
Fuel Filter.........................................................................................................................22501
Fuel Gauge Unit.....................................................................................................................22502
Fuel Injectors......................................................................................................................22503
Fuel Metering System................................................................................................................22504
Fuel Pump Assembly..................................................................................................................22504
Fuel Pump Relay.....................................................................................................................22505
Fuel Rail Assembly..................................................................................................................22506
Fuel Tank...........................................................................................................................22507
Throttle Body (TB)..................................................................................................................22507
Electronic Ignition System..........................................................................................................22509
Catalytic Converter.................................................................................................................22510
Air Conditioning Thermo Relay.......................................................................................................22510
EVAP Canister Hoses.................................................................................................................22510
EVAP Canister.......................................................................................................................22511
EVAP Canister Vent Solenoid.........................................................................................................22511
Fuel Tank Pressure (Vapor Pressure) Sensor..........................................................................................22512
EVAP Canister Purge Solenoid (Purge Duty Solenoid Valve)............................................................................22513
Fuel Tank Vent Valve (Vent Solenoid Valve)..........................................................................................22514
Linear Exhaust Gas Recirculation (EGR) Valve........................................................................................22514
Positive Crankcase Ventilation (PCV) Valve..........................................................................................22515
Wiring and Connectors...............................................................................................................22515
PCM Connectors and Terminals........................................................................................................22516
Wire Harness Repair: Twisted Shielded Cable.........................................................................................22516
Twisted Leads.......................................................................................................................22517
Weather-Pack Connector..............................................................................................................22518
Com-Pack III........................................................................................................................22519
Metri-Pack..........................................................................................................................22520
General Description (PCM and Sensors)...............................................................................................22521
General Description (Air Induction).................................................................................................22526
General Description (Fuel Metering).................................................................................................22527
General Description (Electronic Ignition System)....................................................................................22529
A/C Clutch Diagnosis................................................................................................................22532
General Description (Evaporative (EVAP) Emission System)............................................................................22532
General Description (Exhaust Gas Recirculation (EGR) System)........................................................................22537
General Description (Positive Crankcase Ventilation (PCV) System)...................................................................22538
Special Tools.......................................................................................................................22540
6F ENGINE EXHAUST.......................................................................................................................22542
Service Precaution..................................................................................................................22542
General Description.................................................................................................................22543
Three Way Catalytic Converter RH and Forked Exhaust Pipe............................................................................22544
Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated
Parts...................................................22544
Removal.........................................................................................................................22544
Installation....................................................................................................................22544
Three Way Catalytic Converter LH and Forked Exhaust Pipe............................................................................22545
Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated
Parts...................................................22545
Removal.........................................................................................................................22545
Installation....................................................................................................................22545
Forked Exhaust Pipe.................................................................................................................22546
Forked Exhaust Pipe and Associated Parts........................................................................................22546
Removal.........................................................................................................................22546
Installation....................................................................................................................22546
Exhaust Silencer....................................................................................................................22547
Exhaust Silencer and Associated Parts...........................................................................................22547
Removal.........................................................................................................................22547
Installation....................................................................................................................22547
Rear Exhaust pipe...................................................................................................................22548
Rear Exhaust pipe and Associated Parts..........................................................................................22548
Removal.........................................................................................................................22548
Installation....................................................................................................................22548
Main Data and Specifications........................................................................................................22549
6G ENGINE LUBRICATION...................................................................................................................22550
Service Precaution..................................................................................................................22550
General Description.................................................................................................................22551
Oil Pump............................................................................................................................22552
Oil Pump and Associated Parts...................................................................................................22552
Disassembly.....................................................................................................................22553
Inspection and Repair...........................................................................................................22553
Reassembly......................................................................................................................22554
Oil Pan and Crankcase...............................................................................................................22556
Removal.........................................................................................................................22556
Installation....................................................................................................................22556
Oil Pump............................................................................................................................22558
Removal.........................................................................................................................22558
Installation....................................................................................................................22558
Oil Pump Oil Seal...................................................................................................................22560
Removal.........................................................................................................................22560
Installation....................................................................................................................22560
Oil Filter..........................................................................................................................22561
Removal.........................................................................................................................22561
Installation....................................................................................................................22561
Main Data and Specification.........................................................................................................22562
6H ENGINE SPEED CONTROL SYSTEM..........................................................................................................22563
Service Precaution..................................................................................................................22563
Accelerator Pedal...................................................................................................................22564
Accelerator Pedal and Associated Parts..........................................................................................22564
Removal.........................................................................................................................22564
Installation....................................................................................................................22564
6J INDUCTION............................................................................................................................22565
Service Precaution..................................................................................................................22565
Air Cleaner Element.................................................................................................................22566
Removal.........................................................................................................................22566
Inspection......................................................................................................................22566
Installation....................................................................................................................22566
Sec.7 TRANSMISSION..............................................................................................................................22567
7A AUTOMATIC TRANSMISSION...................................................................................................................22567
Service Precaution......................................................................................................................22568
Construction............................................................................................................................22569
Range Reference Chart...................................................................................................................22570
Normal Operation of 2001 4L30–E Transmission............................................................................................22571
Diagnosis...............................................................................................................................22571
Driver Information......................................................................................................................22571
General Diagnosis Procedure.............................................................................................................22574
Preliminary Inspection Chart............................................................................................................22575
Checking Transmission Fluid Level
and Condition.........................................................................................22576
Test Driving............................................................................................................................22577
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................22578
Mechanical / Hydraulic Diagnosis Symptoms Index.........................................................................................22579
Stall Test..............................................................................................................................22588
Line Pressure Test......................................................................................................................22589
Shift Speed Chart (V6)..................................................................................................................22591
Lockup Speed Chart (V6).................................................................................................................22592
Shift Speed Chart (HEC).................................................................................................................22593
Lockup Speed Chart (HEC)................................................................................................................22594
Changing Transmission Fluid.............................................................................................................22595
Selector Lever..........................................................................................................................22595
Inspection..........................................................................................................................22595
Removal.............................................................................................................................22595
Installation........................................................................................................................22597
Select Cable............................................................................................................................22597
Removal.............................................................................................................................22597
Installation........................................................................................................................22600
Shift Lock Cable........................................................................................................................22602
Removal.............................................................................................................................22602
Installation........................................................................................................................22602
Mode Switch.............................................................................................................................22603
Removal.............................................................................................................................22603
Installation........................................................................................................................22604
Transmission Assembly...................................................................................................................22605
Transmission and Associated Parts...................................................................................................22605
Removal.............................................................................................................................22607
Installation........................................................................................................................22614
Solenoid (Main Case Valve Body).........................................................................................................22621
Removal.............................................................................................................................22621
Installation........................................................................................................................22621
Solenoid (Adapter Case Valve Body)......................................................................................................22622
Removal.............................................................................................................................22622
Installation........................................................................................................................22622
Valve Body Assembly (Main Case).........................................................................................................22623
Removal.............................................................................................................................22623
Installation........................................................................................................................22623
Valve Body Assembly (Adapter Case)......................................................................................................22624
Removal.............................................................................................................................22624
Installation........................................................................................................................22624
Powertrain Control Module (PCM) (V6)....................................................................................................22625
Removal.............................................................................................................................22625
Installation........................................................................................................................22625
Powertrain Control Module (PCM) (HEC)...................................................................................................22626
Removal.............................................................................................................................22626
Installation........................................................................................................................22626
Speed Sensor (Extension Assembly).......................................................................................................22627
Removal.............................................................................................................................22627
Installation........................................................................................................................22627
Transmission Oil Temperature Sensor (Main Case) (V6)....................................................................................22628
Removal.............................................................................................................................22628
Installation........................................................................................................................22628
Transmission Oil Temperature Sensor (Adapter Case) (HEC)................................................................................22629
Removal.............................................................................................................................22629
Installation........................................................................................................................22629
Front Oil Seal (Converter Housing)......................................................................................................22630
Removal.............................................................................................................................22630
Installation........................................................................................................................22630
Rear Oil Seal (Extension Assembly)......................................................................................................22631
Removal.............................................................................................................................22631
Installation........................................................................................................................22631
Transmission (4L30–E)...................................................................................................................22632
Disassembly.........................................................................................................................22632
Reassembly..........................................................................................................................22637
Converter Housing and Oil Pump Assembly.................................................................................................22648
Disassembled View...................................................................................................................22648
Disassembly.........................................................................................................................22648
Inspection and Repair...............................................................................................................22648
Reassembly..........................................................................................................................22648
Oil Pump................................................................................................................................22649
Disassembled View...................................................................................................................22649
Disassembly.........................................................................................................................22649
Inspection and Repair...............................................................................................................22649
Reassembly..........................................................................................................................22649
Main Case Valve Body....................................................................................................................22650
Disassembled View...................................................................................................................22650
Disassembly.........................................................................................................................22651
Inspection and Repair...............................................................................................................22651
Reassembly..........................................................................................................................22651
Adapter Case Valve Body.................................................................................................................22652
Disassembled View...................................................................................................................22652
Disassembly.........................................................................................................................22652
Inspection and Repair...............................................................................................................22652
Reassembly..........................................................................................................................22652
Third Clutch and Sprag Unit.............................................................................................................22653
Disassembled View...................................................................................................................22653
Disassembly.........................................................................................................................22653
Inspection and Repair...............................................................................................................22654
Reassembly..........................................................................................................................22654
Third Clutch............................................................................................................................22654
Disassembled View...................................................................................................................22654
Disassemble.........................................................................................................................22655
Inspection and Repair...............................................................................................................22655
Reassembly..........................................................................................................................22655
Sprag Unit..............................................................................................................................22656
Disassembled View...................................................................................................................22656
Disassembly.........................................................................................................................22656
Inspection and Repair...............................................................................................................22656
Reassembly..........................................................................................................................22656
Second Clutch...........................................................................................................................22657
Disassembled View...................................................................................................................22657
Disassembly.........................................................................................................................22657
Inspection and Repair...............................................................................................................22658
Reassembly..........................................................................................................................22658
3–4 Accumulator Piston..................................................................................................................22659
Disassembled View...................................................................................................................22659
Disassembly.........................................................................................................................22659
Inspection and Repair...............................................................................................................22660
Reassembly..........................................................................................................................22660
Reverse Clutch Piston and Center Support................................................................................................22661
Disassembled View...................................................................................................................22661
Disassembly.........................................................................................................................22662
Inspection and Repair...............................................................................................................22662
Reassembly..........................................................................................................................22662
Overrun Clutch and Turbine Shaft........................................................................................................22663
Disassembled View...................................................................................................................22663
Disassembly.........................................................................................................................22664
Inspection and Repair...............................................................................................................22664
Reassembly..........................................................................................................................22664
Main Data and Specification.............................................................................................................22666
General Specifications..............................................................................................................22666
Torque Specifications...............................................................................................................22667
Special Tools...........................................................................................................................22672
4L30–E Parts List.......................................................................................................................22675
7A1 TRANSMISSION CONTROL SYSTEM.............................................................................................................22682
Service Precaution......................................................................................................................22683
General Description.....................................................................................................................22683
Electronic Control Diagram..........................................................................................................22684
Powertrain Control Module (PCM).....................................................................................................22685
Control System Diagram..............................................................................................................22686
Shift Control.......................................................................................................................22687
Band Apply Control..................................................................................................................22687
Torque Converter Clutch Control.....................................................................................................22687
Line Pressure Control...............................................................................................................22687
On–Board Diagnostic System..........................................................................................................22687
Fail–Safe Mechanism.................................................................................................................22687
Torque Management Control...........................................................................................................22687
ATF Warning Control.................................................................................................................22687
Reverse Lock Out Control............................................................................................................22687
Downhill Control....................................................................................................................22687
Uphill Control......................................................................................................................22687
Shift Mode Control..................................................................................................................22688
Gear Shift Control..................................................................................................................22689
Winter Drive Mode...................................................................................................................22690
Backup Mode.........................................................................................................................22690
Functions of Input / Output Components..............................................................................................22691
Diagnosis...............................................................................................................................22692
Electronic Diagnosis................................................................................................................22692
Check Trans Indicator...............................................................................................................22692
Diagnostic Check....................................................................................................................22692
“Check Trans” Check.................................................................................................................22693
Tech 2 OBD II Connection............................................................................................................22694
Transmission Data...................................................................................................................22699
OBD II Diagnostic Management System.................................................................................................22700
16 – Terminal Data Link Connector (DLC).............................................................................................22701
Malfunction Indicator Lamp (MIL)....................................................................................................22702
DTC Types...........................................................................................................................22702
Clear DTC...........................................................................................................................22703
DTC Check...........................................................................................................................22703
PCM Precaution......................................................................................................................22703
Information On PCM..................................................................................................................22703
Intermittent Conditions.............................................................................................................22704
Transmission and PCM Identification.................................................................................................22705
Diagnostic Trouble Code (DTC)
Identification........................................................................................22706
DTC P0218 Transmission Fluid Over Temperature...........................................................................................22707
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position......................................................................22709
DTC P0706 Transmission Range Switch (Mode Switch) Performance...........................................................................22712
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance.......................................................................22715
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input.................................................................22718
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................22721
DTC P0719 Brake Switch Circuit Low (Stuck On)...........................................................................................22724
DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input....................................................................22727
DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent.................................................................22730
DTC P0724 Brake Switch Circuit High (Stuck Off).........................................................................................22733
DTC P0730 Gear Error Without Input Speed................................................................................................22735
DTC P0742 Torque Converter Clutch (TCC) System Stuck On.................................................................................22738
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical..............................................................22740
DTC P0751 Shift Solenoid A Performance (Stuck Off)......................................................................................22742
DTC P0752 Shift Solenoid A Performance (Stuck On).......................................................................................22744
DTC P0753 Shift Solenoid A Electrical...................................................................................................22746
DTC P0756 Shift Solenoid B Performance (Stuck Off)......................................................................................22749
DTC P0757 Shift Solenoid B Performance (Stuck On).......................................................................................22751
DTC P0758 Shift Solenoid B Electrical...................................................................................................22753
DTC P1850 Brake Band Apply Solenoid Malfunction.........................................................................................22757
DTC P1860 TCC Solenoid Electrical.......................................................................................................22761
DTC P1870 Transmission Component Slipping (TCC Stuck Off)...............................................................................22764
Circuit Diagram.........................................................................................................................22766
Parts Location..........................................................................................................................22768
Harness Connector Faces.................................................................................................................22769
7B MANUAL TRANSMISSION MUA 5C...............................................................................................................22771
Service Precaution......................................................................................................................22771
General Description.....................................................................................................................22772
Diagnosis...............................................................................................................................22774
Rear Oil Seal (4X2).....................................................................................................................22775
Disassembled View...................................................................................................................22775
Removal.............................................................................................................................22775
Installation........................................................................................................................22775
Transmission............................................................................................................................22776
Disassembled View...................................................................................................................22776
Removal.............................................................................................................................22777
Installation........................................................................................................................22781
Transmission Case.......................................................................................................................22786
Major Component (4X2)...............................................................................................................22786
Disassembly.........................................................................................................................22787
Reassembly..........................................................................................................................22788
Transmission Case and Transfer Case.....................................................................................................22791
Major Component (4X4)...............................................................................................................22791
Disassembly.........................................................................................................................22792
Reassembly..........................................................................................................................22795
Intermediate Plate with Gear Assembly, Detent, Shift Arm,
and Interlock Pin.............................................................22801
Disassembled View...................................................................................................................22801
Disassembly.........................................................................................................................22802
Inspection and Repair...............................................................................................................22803
Reassembly..........................................................................................................................22804
Reverse Gear and 5th Gear...............................................................................................................22805
Disassembled View...................................................................................................................22805
Disassembly.........................................................................................................................22806
Inspection and Repair...............................................................................................................22808
Reassembly..........................................................................................................................22808
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft.................................................................................22814
Disassmebled View...................................................................................................................22814
Disassembly.........................................................................................................................22815
Inspection and Repair...............................................................................................................22816
Reassembly..........................................................................................................................22819
Main Data and Specifications............................................................................................................22825
Special Tools (MUA).....................................................................................................................22829
7C CLUTCH...................................................................................................................................22831
Service Precaution......................................................................................................................22831
General Description.....................................................................................................................22832
Diagnosis...............................................................................................................................22837
Clutch Assembly (Y22SE).................................................................................................................22838
Clutch Assembly (Y22SE) and Associated Parts........................................................................................22838
Removal.............................................................................................................................22838
Inspection and Repair...............................................................................................................22839
Installation........................................................................................................................22843
Clutch Assembly (6VD1)..................................................................................................................22845
Clutch Assembly (6VD1) and Associated Parts.........................................................................................22845
Removal.............................................................................................................................22845
Inspection and Repair...............................................................................................................22847
Installation........................................................................................................................22851
Clutch Control..........................................................................................................................22853
Parts Location View.................................................................................................................22853
Removal.............................................................................................................................22854
Inspection and Repair...............................................................................................................22854
Installation........................................................................................................................22854
Master Cylinder.........................................................................................................................22857
Slave Cylinder..........................................................................................................................22858
Disassembled View...................................................................................................................22858
Disassembly.........................................................................................................................22858
Inspection and Repair...............................................................................................................22858
Reassembly..........................................................................................................................22859
Main Data and Specifications............................................................................................................22860
Special Tools...........................................................................................................................22863
Sec.8 BODY AND ACCESSORIES......................................................................................................................22864
8A LIGHTING SYSTEM..........................................................................................................................22864
Service Precaution......................................................................................................................22865
Headlight Bulb..........................................................................................................................22866
Headlight Assembly......................................................................................................................22866
Headlight Adjustment................................................................................................................22867
Fog Light Bulb..........................................................................................................................22869
Fog Light Assembly......................................................................................................................22870
Fog Light Adjustment................................................................................................................22870
Side Marker Light Bulb..................................................................................................................22870
Taillight Bulb..........................................................................................................................22871
License Plate Light Bulb (Bumper Type)..................................................................................................22871
License Plate Light Bulb (Tailgate Type)................................................................................................22872
Stoplight Bulb..........................................................................................................................22872
High Mounted Stoplight Assembly.........................................................................................................22873
High Mounted Stoplight Bulb.............................................................................................................22873
High Mounted Stoplight Assembly (Soft Top Model)........................................................................................22874
High Mounted Stoplight Bulb (Soft Top Model)............................................................................................22874
High Mounted Stoplight Assembly (Resin Top Model).......................................................................................22875
High Mounted Stoplight Bulb (Resin Top Model)...........................................................................................22875
Backup Light Bulb.......................................................................................................................22876
Front Turn Signal Light Bulb............................................................................................................22876
Rear Turn Signal Light Bulb.............................................................................................................22877
Dome Light Bulb (LWB)...................................................................................................................22877
Dome Light Bulb (SWB)...................................................................................................................22878
Courtesy Light Bulb.....................................................................................................................22878
Spotlight Bulb..........................................................................................................................22879
Luggage Room Light Bulb (LWB)...........................................................................................................22879
Luggage Room Light Bulb (Resin Top Model)...............................................................................................22880
HVAC Bezel Illumination Light Bulb......................................................................................................22880
Shift Lever Illumination Light Bulb (A/T)...............................................................................................22881
Vanity Mirror Illumination Light Bulb...................................................................................................22881
Starter Switch..........................................................................................................................22882
Lighting Switch (Combination Switch)....................................................................................................22882
Dimmer・Passing Switch (Combination Switch)..............................................................................................22882
Door Switch.............................................................................................................................22882
Rear Defogger Switch....................................................................................................................22883
Key Remind Switch (Starter Switch)......................................................................................................22883
Hazard Warning Light Switch.............................................................................................................22884
Stoplight Switch........................................................................................................................22884
Backup Light Switch (M/T)...............................................................................................................22885
Turn Signal Light Switch (Combination Switch)...........................................................................................22885
Illumination Controller.................................................................................................................22886
Light and Bulb Specifications (LWB).....................................................................................................22887
Light and Bulb Specifications (SWB).....................................................................................................22888
8B WIPER / WASHER SYSTEM....................................................................................................................22890
Service Precaution......................................................................................................................22890
Windshield Wiper/Washer System..........................................................................................................22891
General Description.................................................................................................................22891
Windshield Wiper And Washer Switch......................................................................................................22891
Removal and Installation............................................................................................................22891
Windshield Wiper Motor..................................................................................................................22891
Removal.............................................................................................................................22891
Installation........................................................................................................................22891
Windshield Washer Motor.................................................................................................................22892
Removal.............................................................................................................................22892
Installation........................................................................................................................22892
Windshield Washer Spray Pattern.........................................................................................................22893
Windshield Wiper Linkage................................................................................................................22894
Windshield Wiper Linkage and Associated Parts.......................................................................................22894
Removal.............................................................................................................................22894
Installation........................................................................................................................22894
Windshield Wiper Arm/Blade..............................................................................................................22895
Removal.............................................................................................................................22895
Installation........................................................................................................................22895
Windshield Wiper Blade Rubber...........................................................................................................22896
Removal.............................................................................................................................22896
Installation........................................................................................................................22896
Rear Wiper/Washer System................................................................................................................22897
General Description.................................................................................................................22897
Rear Wiper and Washer Switch............................................................................................................22897
Removal.............................................................................................................................22897
Installation........................................................................................................................22897
Rear Wiper Motor (LWB)..................................................................................................................22898
Removal.............................................................................................................................22898
Installation........................................................................................................................22898
Rear Wiper Motor (Resin Top Model)......................................................................................................22899
Removal.............................................................................................................................22899
Installation........................................................................................................................22899
Rear Washer Motor.......................................................................................................................22900
Removal.............................................................................................................................22900
Installation........................................................................................................................22900
Alarm and Relay Control Unit............................................................................................................22901
Removal.............................................................................................................................22901
Installation........................................................................................................................22901
Rear Wiper Arm/Blade (LWB)..............................................................................................................22901
Removal.............................................................................................................................22901
Installation........................................................................................................................22901
Rear Wiper Arm/Blade (Resin Top Model)..................................................................................................22902
Removal.............................................................................................................................22902
Installation........................................................................................................................22902
Rear Washer Nozzle......................................................................................................................22902
Removal.............................................................................................................................22902
Installation........................................................................................................................22902
Rear Washer Spray Pattern...........................................................................................................22902
Rear Washer Nozzle (Resin Top Model)....................................................................................................22903
Removal.............................................................................................................................22903
Installation........................................................................................................................22903
Rear Washer Spray Pattern...........................................................................................................22903
Rear Wiper Blade Rubber (Spare Tire Storage-Tailgate Mounted)...........................................................................22904
Removal.............................................................................................................................22904
Installation........................................................................................................................22904
Rear Wiper Blade Rubber (Spare Tire Storage-Under Floor)................................................................................22905
Removal.............................................................................................................................22905
Installation........................................................................................................................22905
Main Data and Specifications............................................................................................................22906
8C ENTERTAINMENT............................................................................................................................22907
Service Precaution......................................................................................................................22907
Cigarette Lighter.......................................................................................................................22908
General Description.................................................................................................................22908
Removal.............................................................................................................................22908
Installation........................................................................................................................22908
Digital Clock...........................................................................................................................22908
Removal.............................................................................................................................22908
Installation........................................................................................................................22908
Rod Type Antenna........................................................................................................................22909
Removal.............................................................................................................................22909
Installation........................................................................................................................22909
Accessory Socket........................................................................................................................22910
Front Accessory Socket..............................................................................................................22910
Rear Accessory Socket...............................................................................................................22910
Radio...................................................................................................................................22911
Removal.............................................................................................................................22911
Installation........................................................................................................................22911
Amplifier...............................................................................................................................22912
Removal.............................................................................................................................22912
Installation........................................................................................................................22912
Speaker.................................................................................................................................22913
Front Speaker.......................................................................................................................22913
Tweeter Assembly....................................................................................................................22913
Rear Door Speaker (LWB).............................................................................................................22913
Rear Speaker (LWB)..................................................................................................................22914
Rear Speaker (SWB)..................................................................................................................22914
Horn....................................................................................................................................22915
Removal.............................................................................................................................22915
Installation........................................................................................................................22915
8D WIRING SYSTEM............................................................................................................................22916
Fuse, Relay and Diode...................................................................................................................22917
Relay / Fuse Box Location...........................................................................................................22917
Relay / Fuse Box (Instrument Panel).................................................................................................22918
Relay / Fuse Box (L4 Engine Room)...................................................................................................22919
Relay / Fuse Box (V6 Engine Room)...................................................................................................22920
Circuit Diagram.........................................................................................................................22921
Fuse Block Circuit-1 (L4)...........................................................................................................22921
Fuse Block Circuit-2 (V6)...........................................................................................................22922
Earth Location (Engine Room)........................................................................................................22923
Earth Location (Cabin)..............................................................................................................22924
Starter and Generator (L4)..........................................................................................................22925
Starter and Generator (V6)..........................................................................................................22926
ECM (L4)............................................................................................................................22927
PCM (V6)-1..........................................................................................................................22928
PCM (V6)-2..........................................................................................................................22929
Headlight and Fog Light.............................................................................................................22930
TURN, HAZARD, STOP, Back Up, Horn and A/T Shift Lock................................................................................22931
Room, Luggage, Courtesy, Spot, Warning Buzzer (LWB).................................................................................22932
Room, Luggage, Courtesy, Spot, Warning Buzzer (SWB).................................................................................22933
Power Window and Door Lock..........................................................................................................22934
Alarmer Unit........................................................................................................................22935
Rear Wiper/Washer, Rear Defogger and Mirror Defogger................................................................................22936
Audio, Clock, Cigarette Lighter and ACC Socket (W/O AMP)............................................................................22937
Audio, Clock, Cigarette Lighter and ACC Socket (W/AMP)..............................................................................22938
Door Mirror.........................................................................................................................22939
Meter (L4)..........................................................................................................................22940
Meter (V6)-1........................................................................................................................22941
Meter (V6)-2........................................................................................................................22942
Anti-theft with Keyless Entry (LWB).................................................................................................22943
Anti-theft with Keyless Entry (L4 SWB)..............................................................................................22944
Anti-theft with Keyless Entry (V6 SWB)..............................................................................................22945
Air Conditioning....................................................................................................................22946
ABS.................................................................................................................................22947
SRS-Air Bag.........................................................................................................................22948
Intelligent Suspension..............................................................................................................22949
Shift on the Fly....................................................................................................................22950
Sunroof.............................................................................................................................22951
Illumination Light..................................................................................................................22952
FRT Wiper...........................................................................................................................22953
Power Seat..........................................................................................................................22954
8E METER AND GAUGE..........................................................................................................................22955
Service Precaution......................................................................................................................22955
General Description.................................................................................................................22955
Meter Assembly..........................................................................................................................22956
General Description.................................................................................................................22956
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights..................................................22956
Table for Meter/Gauge Connector Terminal Connections................................................................................22958
Removal.............................................................................................................................22960
Installation........................................................................................................................22960
Warning Light Bulb and Indicator Light Bulb.............................................................................................22960
Removal.............................................................................................................................22960
Installation........................................................................................................................22960
A/T Shift Indicator Light Bulb..........................................................................................................22961
Removal.............................................................................................................................22961
Installation........................................................................................................................22962
Vehicle Speed Sensor....................................................................................................................22962
Removal.............................................................................................................................22962
Installation........................................................................................................................22962
Fuel Tank Unit..........................................................................................................................22963
Main Data and Specifications............................................................................................................22964
8F BODY STRUCTURE...........................................................................................................................22965
Service Precaution......................................................................................................................22966
Frame...................................................................................................................................22966
General Description.................................................................................................................22966
Frame Dimensions (LWB)..............................................................................................................22967
Frame Dimensions (SWB)..............................................................................................................22968
General Description (Bumper)........................................................................................................22969
Front Bumper............................................................................................................................22969
Parts Location......................................................................................................................22969
Removal.............................................................................................................................22970
Installation........................................................................................................................22970
Front Bumper Slider Bracket.............................................................................................................22971
Removal.............................................................................................................................22971
Installation........................................................................................................................22971
Rear Bumper.............................................................................................................................22972
Parts Location (Spare tire mounted tailgate model)..................................................................................22972
Removal.............................................................................................................................22973
Installation........................................................................................................................22973
Parts Location (Spare tire mounted under floor model)...............................................................................22975
Removal.............................................................................................................................22976
Installation........................................................................................................................22976
Rear Bumper Slider......................................................................................................................22977
Removal.............................................................................................................................22977
Installation........................................................................................................................22977
General Description (Sheet Metal)...................................................................................................22978
Engine Hood.............................................................................................................................22978
Parts Location......................................................................................................................22978
Removal.............................................................................................................................22979
Installation........................................................................................................................22979
Engine Hood Lock........................................................................................................................22981
Parts Location......................................................................................................................22981
Removal.............................................................................................................................22981
Installation........................................................................................................................22982
Radiator Grille.........................................................................................................................22983
Parts Location......................................................................................................................22983
Removal.............................................................................................................................22983
Installation........................................................................................................................22984
Front Fender Panel......................................................................................................................22985
Parts Location......................................................................................................................22985
Removal.............................................................................................................................22985
Installation........................................................................................................................22986
Body Mounting...........................................................................................................................22988
Parts Location......................................................................................................................22988
Tightening Torque...................................................................................................................22988
Body Dimension..........................................................................................................................22989
Front Section.......................................................................................................................22989
Room Section (SWB)..................................................................................................................22992
Room Section (LWB)..................................................................................................................22994
Rear Section (SWB)..................................................................................................................22996
Rear Section (LWB)..................................................................................................................22998
Side Body Section (Front side)......................................................................................................23000
Side Body Section (Rear side).......................................................................................................23002
General Description (Body)..........................................................................................................23004
Instrument Panel Assembly...............................................................................................................23004
Parts Location......................................................................................................................23004
Removal.............................................................................................................................23005
Installation........................................................................................................................23006
Front Door Assembly.....................................................................................................................23007
Parts Location......................................................................................................................23007
Removal.............................................................................................................................23007
Installation........................................................................................................................23008
Rear Door Assembly......................................................................................................................23009
Parts Location......................................................................................................................23009
Removal.............................................................................................................................23009
Installation........................................................................................................................23010
Front Window Regulator, Glass and Glass Run.............................................................................................23011
Parts Location......................................................................................................................23011
Removal.............................................................................................................................23012
Installation........................................................................................................................23014
Rear Window Regulator, Glass and Glass Run..............................................................................................23015
Parts Location......................................................................................................................23015
Removal.............................................................................................................................23016
Installation........................................................................................................................23018
Tailgate (LWB)..........................................................................................................................23019
Parts Location......................................................................................................................23019
Removal.............................................................................................................................23020
Installation........................................................................................................................23021
Tailgate (SWB)..........................................................................................................................23022
Parts Location......................................................................................................................23022
Removal.............................................................................................................................23023
Installation........................................................................................................................23023
Rear Hatchgate (LWB)....................................................................................................................23024
Parts Location......................................................................................................................23024
Removal.............................................................................................................................23025
Installation........................................................................................................................23025
Adjustment..........................................................................................................................23027
Tailgate Glass (Resin Top)..............................................................................................................23028
Parts Location......................................................................................................................23028
Removal.............................................................................................................................23029
Installation........................................................................................................................23029
Spare Tire Carrier......................................................................................................................23030
Parts Location......................................................................................................................23030
Removal.............................................................................................................................23030
Installation........................................................................................................................23030
Spare Tire Hanger.......................................................................................................................23031
Parts Location......................................................................................................................23031
Removal.............................................................................................................................23032
Installation........................................................................................................................23032
Windshield..............................................................................................................................23033
Parts Location......................................................................................................................23033
Removal.............................................................................................................................23034
Installation........................................................................................................................23034
Rear Quarter Glass (LWB)................................................................................................................23037
Parts Location......................................................................................................................23037
Removal.............................................................................................................................23037
Installation........................................................................................................................23038
Rear Quarter Glass (Resin Top)..........................................................................................................23039
Parts Location......................................................................................................................23039
Removal.............................................................................................................................23039
Installation........................................................................................................................23039
Side Window Glass (SWB).................................................................................................................23041
Parts Location......................................................................................................................23041
Removal.............................................................................................................................23041
Installation........................................................................................................................23041
Main Data and Specifications............................................................................................................23042
Special Tools...........................................................................................................................23045
8G SEATS....................................................................................................................................23046
Service Precaution......................................................................................................................23046
Front Seat Assembly.....................................................................................................................23047
Front Seat Assembly and Associated Parts............................................................................................23047
Removal.............................................................................................................................23047
Installation........................................................................................................................23048
Power Seat Assembly.....................................................................................................................23050
Power Seat Assembly and Associated Parts............................................................................................23050
Removal.............................................................................................................................23051
Installation........................................................................................................................23052
Rear Seat Assembly (LWB)................................................................................................................23053
Rear Seat Cushion Assembly and Associated Parts.....................................................................................23053
Removal.............................................................................................................................23054
Installation........................................................................................................................23054
Rear Seat Back Assembly and Associated Parts........................................................................................23055
Removal.............................................................................................................................23055
Installation........................................................................................................................23056
Rear Seat Assembly (SWB)................................................................................................................23057
Rear Seat Assembly and Associated Parts.............................................................................................23057
Removal.............................................................................................................................23058
Installation........................................................................................................................23058
Main Data and Specifications............................................................................................................23059
8H SECURITY AND LOCKS.......................................................................................................................23061
Service Precaution......................................................................................................................23061
Front Door Lock Assembly................................................................................................................23062
Front Door Lock Assembly and Associated Parts.......................................................................................23062
Removal.............................................................................................................................23063
Installation........................................................................................................................23064
Front Outside Handle....................................................................................................................23065
Front Outside Handle and Associated Parts...........................................................................................23065
Removal.............................................................................................................................23065
Installation........................................................................................................................23065
Rear Door Lock Assembly.................................................................................................................23066
Rear Door Lock Assembly and Associated Parts........................................................................................23066
Removal.............................................................................................................................23066
Installation........................................................................................................................23067
Rear Outside Handle.....................................................................................................................23068
Rear Outside Handle and Associated Parts............................................................................................23068
Removal.............................................................................................................................23068
Installation........................................................................................................................23068
Tailgate Lock and Hatchgate Lock (LWB)..................................................................................................23069
Tailgate Lock, Hatchgate Lock and Associated Parts..................................................................................23069
Removal.............................................................................................................................23069
Installation........................................................................................................................23070
Tailgate Lock (SWB).....................................................................................................................23071
Tailgate Lock and Associated Parts..................................................................................................23071
Removal.............................................................................................................................23071
Installation........................................................................................................................23072
Key.....................................................................................................................................23073
Key Coding..........................................................................................................................23073
Key Styles..........................................................................................................................23073
Power Door Lock System..................................................................................................................23074
General Description.................................................................................................................23074
Door Lock Key Switch................................................................................................................23074
Front Door Lock Actuator............................................................................................................23074
Rear Door Lock Actuator.............................................................................................................23074
Tailgate Lock Actuator..............................................................................................................23074
Anti-Theft System.......................................................................................................................23074
General Description.................................................................................................................23074
Anti-Theft & Keyless Entry Controller...............................................................................................23074
Anti–Theft Indicator................................................................................................................23075
Anti–Theft Horn.....................................................................................................................23075
Engine Hood Switch..................................................................................................................23076
Anti–theft & Keyless Entry Control Unit/Transmitter Replacement.....................................................................23076
Keyless Entry System....................................................................................................................23077
ID Code Registration................................................................................................................23077
Main Data and Specifications............................................................................................................23081
8I SUNROOF/CONVERTIBLE TOP.................................................................................................................23082
Service Precaution......................................................................................................................23082
Sunroof Glass (LWB).....................................................................................................................23083
Sunroof Glass and Associated Parts..................................................................................................23083
Removal.............................................................................................................................23083
Installation........................................................................................................................23084
Sunroof Glass (SWB).....................................................................................................................23084
Sunroof Glass and Associated Parts..................................................................................................23084
Removal.............................................................................................................................23085
Installation........................................................................................................................23085
Sunroof Deflector (LWB).................................................................................................................23086
Removal.............................................................................................................................23086
Installation........................................................................................................................23086
Sunroof Deflector (SWB).................................................................................................................23087
Parts Location......................................................................................................................23087
Removal.............................................................................................................................23087
Installation........................................................................................................................23087
Sunshade (LWB)..........................................................................................................................23088
Disassembled View...................................................................................................................23088
Removal.............................................................................................................................23088
Installation........................................................................................................................23089
Sunroof Frame Complete Assembly (LWB)...................................................................................................23090
Sunroof Frame Complete Assembly and Associated Parts................................................................................23090
Removal.............................................................................................................................23090
Installation........................................................................................................................23091
Sunroof Switch..........................................................................................................................23091
Removal.............................................................................................................................23091
Installation........................................................................................................................23091
Sunroof Control Unit....................................................................................................................23092
Removal.............................................................................................................................23092
Installation........................................................................................................................23092
Sunroof Motor...........................................................................................................................23092
Removal.............................................................................................................................23092
Installation........................................................................................................................23092
Soft Top Assembly.......................................................................................................................23093
Soft Top Assembly and Associated Parts..............................................................................................23093
Removal.............................................................................................................................23094
Installation........................................................................................................................23094
Resin Top Assembly......................................................................................................................23095
Resin Top Assembly and Associated Parts.............................................................................................23095
Removal.............................................................................................................................23095
Installation........................................................................................................................23096
Seat Belt Cross Bar Assembly............................................................................................................23097
Seat Belt Cross Bar Assembly and Associated Parts...................................................................................23097
Removal.............................................................................................................................23097
Installation........................................................................................................................23098
Main Data and Specifications............................................................................................................23099
8J EXTERIOR / INTERIOR TRIM.................................................................................................................23100
Service Precaution......................................................................................................................23101
Consoles................................................................................................................................23102
Consoles and Associated Parts.......................................................................................................23102
Removal.............................................................................................................................23102
Installation........................................................................................................................23102
Front Door Trim Panel...................................................................................................................23103
Front Door Trim Panel and Associated Parts..........................................................................................23103
Removal.............................................................................................................................23104
Installation........................................................................................................................23104
Rear Door Trim Panel....................................................................................................................23105
Rear Door Trim Panel and Associated Parts...........................................................................................23105
Removal.............................................................................................................................23106
Installation........................................................................................................................23106
Door Mirror Assembly....................................................................................................................23107
Removal.............................................................................................................................23107
Installation........................................................................................................................23107
Interior Trim Panels (LWB)..............................................................................................................23108
Interior Trim Panels and Associated Parts...........................................................................................23108
Removal.............................................................................................................................23108
Installation........................................................................................................................23110
Interior Trim Panels (SWB)..............................................................................................................23111
Interior Trim Panels and Associated Parts...........................................................................................23111
Removal.............................................................................................................................23111
Installation........................................................................................................................23112
Headlining (LWB)........................................................................................................................23113
Parts Location......................................................................................................................23113
Removal.............................................................................................................................23113
Installation........................................................................................................................23114
Headlining (SWB)........................................................................................................................23115
Parts Location......................................................................................................................23115
Removal.............................................................................................................................23116
Installation........................................................................................................................23117
Wheel Arch Protector (LWB)..............................................................................................................23118
Wheel Arch Protector and Associated Parts...........................................................................................23118
Removal.............................................................................................................................23118
Installation........................................................................................................................23118
Wheel Arch Protector (SWB)..............................................................................................................23119
Wheel Arch Protector and Associated Parts...........................................................................................23119
Removal.............................................................................................................................23119
Installation........................................................................................................................23119
Wheel Arch Molding (SWB)................................................................................................................23120
Wheel Arch Molding and Associated Parts.............................................................................................23120
Removal.............................................................................................................................23120
Installation........................................................................................................................23121
Wheel Arch Molding (LWB)................................................................................................................23122
Wheel Arch Molding and Associated Parts.............................................................................................23122
Removal.............................................................................................................................23122
Installation........................................................................................................................23123
Fuel Filler Door........................................................................................................................23123
Parts Location......................................................................................................................23123
Removal.............................................................................................................................23123
Installation........................................................................................................................23123
Roof Rail...............................................................................................................................23124
Parts Location......................................................................................................................23124
Removal.............................................................................................................................23124
Installation........................................................................................................................23124
License Plate Garnish...................................................................................................................23125
Parts Location......................................................................................................................23125
Removal.............................................................................................................................23125
Installation........................................................................................................................23126
Power Door Mirror System................................................................................................................23126
General Description.................................................................................................................23126
Door Mirror Switch..................................................................................................................23126
Power Window System.....................................................................................................................23127
General Description.................................................................................................................23127
Power Window Switch Driver Seat Side................................................................................................23127
Power Window Motor..................................................................................................................23128
Main Data and Specifications............................................................................................................23129
Sec.9 RESTRAINTS................................................................................................................................23130
9A SEAT BELT SYSTEM.........................................................................................................................23130
Service Precaution......................................................................................................................23130
Front Seat Belt (LWB)...................................................................................................................23131
Front Seat Belt and Associated Parts................................................................................................23131
Removal.............................................................................................................................23131
Inspection..........................................................................................................................23132
Installation........................................................................................................................23132
Front Seat Belt (SWB)...................................................................................................................23133
Front Seat Belt and Associated Parts................................................................................................23133
Removal.............................................................................................................................23133
Inspection..........................................................................................................................23135
Installation........................................................................................................................23135
Rear Seat Belt (LWB)....................................................................................................................23136
Rear Seat Belt and Associated Parts.................................................................................................23136
Removal.............................................................................................................................23136
Inspection..........................................................................................................................23137
Installation........................................................................................................................23138
Rear Seat Belt (SWB)....................................................................................................................23139
Rear Seat Belt and Associated Parts.................................................................................................23139
Removal.............................................................................................................................23139
Inspection..........................................................................................................................23141
Installation........................................................................................................................23141
Front Seat Buckle Assembly..............................................................................................................23142
Removal.............................................................................................................................23142
Installation........................................................................................................................23142
Rear Center Seat Belt / Buckle Assembly.................................................................................................23143
Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................23143
Removal.............................................................................................................................23143
Installation........................................................................................................................23143
Child Seat Tether Anchorage Bracket (Child Restraint)...................................................................................23144
Child Seat Tether Anchorage Bracket and Associated Parts............................................................................23144
Removal.............................................................................................................................23144
Installation........................................................................................................................23144
Child Seat Lower Anchorage Striker (LWB)................................................................................................23145
Child Seat Lower Anchorage Striker and Associated Parts.............................................................................23145
Removal.............................................................................................................................23145
Installation........................................................................................................................23146
Main Data and Specifications............................................................................................................23147
9J SUPPLEMENTAL RESTRAINT SYSTEM (SRS)......................................................................................................23150
Service Precaution......................................................................................................................23150
General Description.....................................................................................................................23151
SRS Component and Wiring Location View..............................................................................................23153
Component Description...................................................................................................................23153
Definition..............................................................................................................................23156
Diagnosis...............................................................................................................................23157
SRS Connector Body Face Views...........................................................................................................23158
Repairs and Inspections Required After an Accident......................................................................................23158
On–Vehicle Service......................................................................................................................23159
Air Bag Assembly Handling /
Shipping / Scrapping........................................................................................23160
Special Tools...........................................................................................................................23175
Service Precaution......................................................................................................................23177
Sensing and Diagnostic Module (SDM).....................................................................................................23179
Service Precautions.................................................................................................................23179
Removal.............................................................................................................................23179
Installation........................................................................................................................23180
Driver Air Bag Assembly.................................................................................................................23181
Service Precautions.................................................................................................................23181
Removal.............................................................................................................................23181
Installation........................................................................................................................23181
Steering Wheel..........................................................................................................................23182
Service Precautions.................................................................................................................23182
Removal.............................................................................................................................23182
Installation........................................................................................................................23183
SRS Coil Assembly.......................................................................................................................23184
Service Precaution..................................................................................................................23184
Removal.............................................................................................................................23184
How to Disconnect the horn terminal.................................................................................................23186
How to Connect Horn Terminal........................................................................................................23186
Installation........................................................................................................................23187
Steering Column.........................................................................................................................23189
Service Precaution..................................................................................................................23189
Removal.............................................................................................................................23189
Installation........................................................................................................................23191
Passenger Air Bag Assembly..............................................................................................................23193
Service Precaution..................................................................................................................23193
Removal.............................................................................................................................23193
Installation........................................................................................................................23193
Main Data and Specifications............................................................................................................23194
SRS Air Bag System Inspection
Standards For Repair......................................................................................23195
9J1 SRS CONTROL SYSTEM......................................................................................................................23196
Service Precaution......................................................................................................................23196
Diagnostic Information..................................................................................................................23197
Plotting Snapshot Graph.................................................................................................................23202
Parts For Electrical Circuit............................................................................................................23205
System Schematic........................................................................................................................23206
SRS Diagnostic System Check.............................................................................................................23206
Chart A SDM Integrity Check.............................................................................................................23209
Chart B “AIR BAG” Warning Lamp Comes “ON” Steady........................................................................................23211
Chart C “AIR BAG” Warning Lamp Does Not Comes “ON” Steady...............................................................................23213
DTC 15 Passenger Deployment Loop Resistance High........................................................................................23216
DTC 16 Passenger Deployment Loop Resistance Low.........................................................................................23219
DTC 17 Passenger Deployment Loop Open...................................................................................................23222
DTC 18 Passenger Deployment Loop Short To Ground........................................................................................23224
DTC 19 Passenger Deployment Loop Short To Voltage.......................................................................................23226
DTC 21 Driver Deployment Loop Resistance High...........................................................................................23228
DTC 22 Driver Deployment Loop Resistance Low............................................................................................23231
DTC 24 Driver Deployment Loop Short To Ground...........................................................................................23234
DTC 25 Driver Deployment Loop Short To Voltage..........................................................................................23236
DTC 26 Driver Deployment Loop Open......................................................................................................23239
DTC 51 Deployment Event Commanded.......................................................................................................23242
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy
Reserves Out Of Range..................................................23244
DTC 61 Warning Lamp Circuit Failure.....................................................................................................23246
DTC 71 Internal SDM Fault...............................................................................................................23248
Sec.10 CONTROL SYSTEM...........................................................................................................................23250
10A CRUISE CONTROL SYSTEM...................................................................................................................23250
Service Precaution......................................................................................................................23250
General Description.....................................................................................................................23250
Brake Switch............................................................................................................................23251
Removal and Installation............................................................................................................23251
Adjustment..........................................................................................................................23251
Clutch Switch...........................................................................................................................23252
Removal and Installation............................................................................................................23252
Adjustment..........................................................................................................................23252
Powertrain Control Module (PCM).........................................................................................................23252
Removal and Installation............................................................................................................23252
Mode Switch.............................................................................................................................23252
Removal and Installation............................................................................................................23252
Cruise Control Main Switch..............................................................................................................23253
Removal.............................................................................................................................23253
Installation........................................................................................................................23253
Cruise Control Switch (Combination Switch)..............................................................................................23253
Removal and Installation............................................................................................................23253
Diagnosis...............................................................................................................................23254
(UA) RODEO SPORT....................................................................................................................................23255
Sec.0 GENRAL INFORMATION........................................................................................................................23256
0A General Information......................................................................................................................23256
0B Maintenance and Lubrication..............................................................................................................23256
Sec.1 HEATING, VENTILATION AND AIR CONDITIONING.................................................................................................23257
1A HVAC System..............................................................................................................................23257
Sec.2 STEERING..................................................................................................................................23258
2A POWER-ASSISTED STEERING SYSTEM...........................................................................................................23258
Service Precaution......................................................................................................................23259
Diagnosis...........................................................................................................................23259
General Description.................................................................................................................23265
Power Steering System Test..........................................................................................................23267
Maintenance.........................................................................................................................23268
Fluid Level.........................................................................................................................23268
Bleeding The Power Steering System..................................................................................................23268
Bleeding Procedure..................................................................................................................23268
Flushing The Power Steering System..................................................................................................23268
Steering Wheel Free Play Inspection.................................................................................................23269
Front End Alignment Inspection and Adjustment.......................................................................................23269
Main Data and Specifications........................................................................................................23273
Special Tools.......................................................................................................................23274
Power Steering Unit.....................................................................................................................23275
Power Steering Unit and Associated Parts............................................................................................23275
Removal.............................................................................................................................23275
Installation (4x2 Model)............................................................................................................23276
Installation (4x4 Model)............................................................................................................23276
Power Steering Unit Disassembled View...............................................................................................23277
Disassembly.........................................................................................................................23277
Inspection and Repair...............................................................................................................23278
Reassembly..........................................................................................................................23278
Main Data and Specifications........................................................................................................23278
Special Tools.......................................................................................................................23279
Power Steering Pump.....................................................................................................................23280
Power Steering Pump and Associated Parts............................................................................................23280
Removal.............................................................................................................................23280
Installation........................................................................................................................23280
Power Steering Pump Disassembled View...............................................................................................23281
Disassembly.........................................................................................................................23281
Inspection and Repair...............................................................................................................23282
Reassembly..........................................................................................................................23282
Main Data and Specifications........................................................................................................23284
Transfer Gear Assembly..................................................................................................................23285
Transfer Gear Assembly and Associated Parts.........................................................................................23285
Removal.............................................................................................................................23285
Inspection and Repair...............................................................................................................23285
Installation........................................................................................................................23285
Supplemental Restraint System Steering Wheel & Column...................................................................................23286
Service Precaution..................................................................................................................23286
SRS Connectors......................................................................................................................23286
Inflator Module.........................................................................................................................23288
Inflator Module and Associated Parts................................................................................................23288
Removal.............................................................................................................................23288
Inspection and Repair...............................................................................................................23289
Installation........................................................................................................................23289
Steering Wheel..........................................................................................................................23290
Steering Wheel and Associated Parts.................................................................................................23290
Removal.............................................................................................................................23290
Installation........................................................................................................................23292
Combination Switch......................................................................................................................23293
Combination Switch and Associated Parts.............................................................................................23293
Removal.............................................................................................................................23293
Installation........................................................................................................................23295
Lock Cylinder...........................................................................................................................23297
Lock Cylinder and Associated Parts..................................................................................................23297
Removal.............................................................................................................................23297
Installation........................................................................................................................23299
System Inspection...................................................................................................................23300
Steering Column.........................................................................................................................23301
Steering Column and Associated Parts................................................................................................23301
Removal.............................................................................................................................23301
Installation........................................................................................................................23303
System Inspection...................................................................................................................23304
Supplemental Restraint System Steering Wheel & Column and Associated Parts..............................................................23305
Main Data and Specifications............................................................................................................23305
Special Tools.......................................................................................................................23305
Sec.3 SUSPENSION................................................................................................................................23306
3C FRONT SUSPENSION.........................................................................................................................23306
Service Precaution......................................................................................................................23306
General Description.................................................................................................................23307
Diagnosis...........................................................................................................................23307
Shock Absorber..........................................................................................................................23311
Shock Absorber and Associated Parts.................................................................................................23311
Removal.............................................................................................................................23311
Inspection and Repair...............................................................................................................23311
Installation........................................................................................................................23311
Stabilizer Bar..........................................................................................................................23312
Stabilizer Bar and Associated Parts.................................................................................................23312
Removal.............................................................................................................................23312
Inspection and Repair...............................................................................................................23312
Installation........................................................................................................................23312
Torsion Bar.............................................................................................................................23313
Torsion Bar and Associated Parts....................................................................................................23313
Removal.............................................................................................................................23313
Inspection and Repair...............................................................................................................23314
Installation........................................................................................................................23314
Knuckle.................................................................................................................................23316
Knuckle and Associated Parts........................................................................................................23316
Removal.............................................................................................................................23316
Inspection and Repair...............................................................................................................23317
Installation........................................................................................................................23317
Upper Control Arm.......................................................................................................................23318
Upper Control Arm and Associated Parts..............................................................................................23318
Removal.............................................................................................................................23318
Inspection and Repair...............................................................................................................23319
Installation........................................................................................................................23319
Lower Control Arm.......................................................................................................................23321
Lower Control Arm and Associated Parts..............................................................................................23321
Removal.............................................................................................................................23321
Inspection and Repair...............................................................................................................23322
Installation........................................................................................................................23323
Upper Ball Joint........................................................................................................................23324
Upper Ball Joint and Associated Parts...............................................................................................23324
Removal.............................................................................................................................23324
Inspection and Repair...............................................................................................................23325
Installation........................................................................................................................23325
Lower Ball Joint........................................................................................................................23326
Lower Ball Joint and Associated Parts...............................................................................................23326
Removal.............................................................................................................................23326
Inspection and Repair...............................................................................................................23327
Installation........................................................................................................................23327
Main Data and Specifications............................................................................................................23328
Special Tools.......................................................................................................................23329
3D REAR SUSPENSION..........................................................................................................................23330
Service Precaution......................................................................................................................23330
General Description.................................................................................................................23330
Diagnosis...........................................................................................................................23331
Coil Spring.............................................................................................................................23334
Coil Spring and Associated Parts....................................................................................................23334
Removal.............................................................................................................................23334
Inspection and Repair...............................................................................................................23335
Installation........................................................................................................................23335
Shock Absorber..........................................................................................................................23336
Shock Absorber and Associated Parts.................................................................................................23336
Removal.............................................................................................................................23336
Inspection and Repair...............................................................................................................23336
Installation........................................................................................................................23336
Trailing Link...........................................................................................................................23337
Trailing Link and Associated Parts..................................................................................................23337
Removal.............................................................................................................................23337
Inspection and Repair...............................................................................................................23337
Installation........................................................................................................................23338
Upper Link..............................................................................................................................23339
Upper Link and Associated Parts.....................................................................................................23339
Removal.............................................................................................................................23339
Inspection and Repair...............................................................................................................23339
Installation........................................................................................................................23340
Lateral Rod.............................................................................................................................23341
Lateral Rod and Associated Parts....................................................................................................23341
Removal.............................................................................................................................23341
Inspection and Repair...............................................................................................................23341
Installation........................................................................................................................23342
Stabilizer Bar..........................................................................................................................23343
Stabilizer Bar and Associated Parts.................................................................................................23343
Removal.............................................................................................................................23343
Inspection and Repair...............................................................................................................23343
Installation........................................................................................................................23344
Main Data and Specifications............................................................................................................23344
Special Tools.......................................................................................................................23346
3E Wheel and Tire System....................................................................................................................23347
3F Intelligent Suspension Control...........................................................................................................23347
Sec.4 DRIVELINE/AXLE............................................................................................................................23349
4A1 Differential (Front)....................................................................................................................23348
4A2 Differential (Rear).....................................................................................................................23348
4B Driveline Control System.................................................................................................................23348
4C DRIVE SHAFT SYSTEM.......................................................................................................................23349
Service Precaution......................................................................................................................23350
Front Propeller Shaft...................................................................................................................23351
General Description.................................................................................................................23351
Diagnosis of Propeller Shaft and Universal Joint....................................................................................23353
Front Propeller Shaft and Associated Parts..........................................................................................23354
Removal.............................................................................................................................23354
Installation........................................................................................................................23354
Slip Joint Disassembly..............................................................................................................23355
Universal Joint Disassembly (Single Cardan Type)....................................................................................23356
Universal Joint Reassembly (Single Cardan Type).....................................................................................23358
Slip Joint Reassembly...............................................................................................................23360
Main Data And Specifications........................................................................................................23361
Rear Propeller Shaft....................................................................................................................23362
General Description.................................................................................................................23362
Diagnosis of Propeller Shaft and Universal Joint....................................................................................23364
Rear Propeller Shaft and Associated Parts...........................................................................................23365
Removal.............................................................................................................................23365
Installation........................................................................................................................23365
Slip Joint Disassembly (6VD1 Model Only)............................................................................................23366
Universal Joint Disassembly.........................................................................................................23367
Inspection..........................................................................................................................23369
Universal Joint Reassembly..........................................................................................................23370
Slip Joint Reassembly (6VD1 Model Only).............................................................................................23371
Main Data and Specifications........................................................................................................23372
4D Transfer Case............................................................................................................................23348
Sec.5 BRAKE CONTROL SYSTEM......................................................................................................................23373
5A Brake Control System.....................................................................................................................23373
5B Anti‐lock Brake System...................................................................................................................23373
5C Power‐assisted Brake System..............................................................................................................23373
5D1 Parking Brakes (4x4 Model)..............................................................................................................23373
5D2 Parking Brakes (4x2 Model)..............................................................................................................23373
Sec.6 ENGINE....................................................................................................................................23375
Y22SE 2.2L ENGINE...........................................................................................................................23375
6A Engine Mechanical....................................................................................................................23374
6B Engine Cooling.......................................................................................................................23374
6C ENGINE FUEL (Y22SE 2.2L) For Short Wheel Base........................................................................................23375
Service Precaution.................................................................................................................. 0
General Description............................................................................................................. 0
Fuel Metering................................................................................................................... 0
Fuel Filter......................................................................................................................... 0
Fuel Filter and Associated Parts................................................................................................ 0
Removal......................................................................................................................... 0
Inspection...................................................................................................................... 0
Installation.................................................................................................................... 0
Inspection...................................................................................................................... 0
In–Tank Fuel Filter............................................................................................................. 0
Fuel Pump Flow Test............................................................................................................. 0
Fuel Pump Relay..................................................................................................................... 0
General Description............................................................................................................. 0
Fuel Tank........................................................................................................................... 0
Fuel Tank and Associated Parts.................................................................................................. 0
Removal......................................................................................................................... 0
Installation.................................................................................................................... 0
Fuel Gauge Unit..................................................................................................................... 0
Removal and Installation........................................................................................................ 0
Fuel Tube / Quick – Connector Fittings.............................................................................................. 0
Precautions..................................................................................................................... 0
Cautions During Work............................................................................................................ 0
Removal......................................................................................................................... 0
Reuse of Quick–Connector........................................................................................................ 0
Assembling Advice............................................................................................................... 0
Fuel Filler Cap..................................................................................................................... 0
General Description............................................................................................................. 0
Inspection...................................................................................................................... 0
Fuel Pump........................................................................................................................... 0
Fuel Pump and Associated Parts.................................................................................................. 0
Removal......................................................................................................................... 0
Installation.................................................................................................................... 0
Main Data and Specifications........................................................................................................ 0
Special Tool.................................................................................................................... 0
6D1 Engine Electrical...................................................................................................................23374
6D2 Ignition System.....................................................................................................................23374
6D3 Starting and Charging System........................................................................................................23374
6E1 Driveability and Emissions..........................................................................................................23374
6F Engine Exhaust.......................................................................................................................23374
6G Engine Lubrication...................................................................................................................23374
6H Engine Speed Control System..........................................................................................................23374
6J Induction............................................................................................................................23374
6VD1 3.2L ENGINE...........................................................................................................................23388
6A Engine Mechanical....................................................................................................................23387
6B Engine Cooling.......................................................................................................................23387
6C ENGINE FUEL For Short Wheel Base.....................................................................................................23388
Service Precaution.................................................................................................................. 0
General Description............................................................................................................. 0
Fuel Metering................................................................................................................... 0
Fuel Filter......................................................................................................................... 0
Removal......................................................................................................................... 0
Inspection...................................................................................................................... 0
Installation.................................................................................................................... 0
Inspection...................................................................................................................... 0
In–Tank Fuel Filter............................................................................................................. 0
Fuel Pump Flow Test............................................................................................................. 0
Fuel Pump........................................................................................................................... 0
Fuel Pump and Associated Parts.................................................................................................. 0
Removal......................................................................................................................... 0
Installation.................................................................................................................... 0
Fuel Tube / Quick – Connector Fittings.............................................................................................. 0
Precautions..................................................................................................................... 0
Cautions During Work............................................................................................................ 0
Removal......................................................................................................................... 0
Reuse of Quick–Connector........................................................................................................ 0
Assembling Advice............................................................................................................... 0
Fuel Pump Relay..................................................................................................................... 0
General Description............................................................................................................. 0
Fuel Tank........................................................................................................................... 0
Fuel Tank and Associated Parts.................................................................................................. 0
Removal......................................................................................................................... 0
Installation.................................................................................................................... 0
Fuel Gauge Unit..................................................................................................................... 0
Removal and Installation........................................................................................................ 0
Fuel Filler Cap..................................................................................................................... 0
General Description............................................................................................................. 0
Inspection...................................................................................................................... 0
Main Data and Specifications........................................................................................................ 0
Special Tool.................................................................................................................... 0
6D1 Engine Electrical...................................................................................................................23387
6D2 Ignition System.....................................................................................................................23387
6D3 Starting and Charging System........................................................................................................23387
6E2 Driveability and Emissions..........................................................................................................23387
6F Engine Exhaust.......................................................................................................................23387
6G Engine Lubrication...................................................................................................................23387
6H Engine Speed Control System..........................................................................................................23387
6J Induction............................................................................................................................23387
Sec.7 AUTOMATIC TRANSMISSION....................................................................................................................23400
7B Manual Transmission......................................................................................................................23400
7C Clutch...................................................................................................................................23400
Sec.8 LIGHTING SYSTME...........................................................................................................................23401
8A Lighting System..........................................................................................................................23401
8B Wiper / Washer System....................................................................................................................23401
8C Entertainment............................................................................................................................23401
8D Wiring System............................................................................................................................23401
8E Meter and Gauge..........................................................................................................................23401
8F Body Structure...........................................................................................................................23401
8G Seats....................................................................................................................................23401
8H Security and Locks.......................................................................................................................23401
8I Sunroof / Convertible Top...............................................................................................................23401
8J Exterior / Interior Trim.................................................................................................................23401
Sec.9 SEAT BELT SYSTEM..........................................................................................................................23402
9A Seat Belt System.........................................................................................................................23402
9J Supplemental Restraint System (RSR)......................................................................................................23402
9J1 Restraint Control System................................................................................................................23402
Sec.10 CRUISE CONTROL SYSTEM....................................................................................................................23403
10A Cruise Control System...................................................................................................................23403
PLEASE NOTE:.
This is the SAME exact manual used by your dealers to fix your vehicle.
The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
Any queries / doubts regarding your purchase, please feel free to contact [email protected]
SK
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