Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Isuzu Trooper Holden Jackaroo 3.2L 3.5L Petrol & 3.0L 3.1L Diesel Shop Manual 1995-2005 – PDF Download
Original price was: $49.95.$29.95Current price is: $29.95.
Isuzu Trooper Holden Jackaroo 3.2L 3.5L Petrol & 3.0L 3.1L Diesel Shop Manual 1995-2005
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Isuzu Trooper Holden Jackaroo 3.2L 3.5L Petrol & 3.0L 3.1L Diesel Shop Manual 1995-2005
FILE DETAILS:
Isuzu Trooper Holden Jackaroo 3.2L 3.5L Petrol & 3.0L 3.1L Diesel Shop Manual 1995-2005
LANGUAGE:ENGLISH
PAGES:11798
DOWNLOADABLE:YES
FILE TYPE:PDF
ISUZU TROOPER HOLDEN JACKAROO 3.2L 3.5L PETROL & 3.0L 3.1L DIESEL SHOP MANUAL 1995-2005 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Isuzu Trooper Holden Jackaroo 3.2L 3.5L Petrol & 3.0L 3.1L Diesel Shop Manual 1995-2005
1.Find the applicable section by referring to the table of contents on the introduction page of each manual.
2. In “Service Information”, an opening section of each manual, the troubleshooting, maintenance servicing, service data and/or information on special tools required for the service operations described in the next subsequent sections are arranged and compiled so concisely that you can see at a first glance.
3. Each section except the Service Information section is basically arranged in the following order of headings: General description On-vehicle service Unit repair
4. The service operations are in two groups: one is the “On-vehicle service” where operations can be directly performed on the vehicle, and the other is the “Unit repair” where the operations are done on the work bench after removing the unit from the vehicle.
5. Each service operation section begins with a disassembled view of unit or equipment, which is useful to find relative components, service procedure, availability and contents of repair kits, etc.
TABLE OF CONTENTS:
Isuzu Trooper Holden Jackaroo 3.2L 3.5L Petrol & 3.0L 3.1L Diesel Shop Manual 1995-2005
TOP.............................................................................................................................................. 0 EXP UBS...................................................................................................................................... 2 1998/1999 MODEL.......................................................................................................................... 0 UBS.................................................................................................................................. 3 Sec.0 GENERAL INFORMATION........................................................................................................ 15 0A GENERAL INFORMATION....................................................................................................... 15 GENERAL REPAIR INSTRUCTIONS.............................................................................................. 16 HOW TO USE THIS MANUAL................................................................................................... 17 IDENTIFICATION........................................................................................................... 20 LIFTING INSTRUCTIONS..................................................................................................... 22 TORQUE SPECIFICATIONS.................................................................................................... 24 RECOMMENDED LIQUID GASKET................................................................................................ 25 RECOMMENDED THREAD LOCKING AGENTS........................................................................................ 25 ABBREVIATIONS CHARTS..................................................................................................... 26 0B MAINTENANCE AND LUBRICATION............................................................................................... 28 MAINTENANCE SCHEDULE..................................................................................................... 29 RECOMMENDED FLUIDS, LUBRICANTS AND FUELS................................................................................. 34 OIL VISCOSITY CHART...................................................................................................... 37 Sec.1 SERVICE INFORMATION........................................................................................................ 40 00 SERVICE INFORMATION....................................................................................................... 40 TROUBLESHOOTING.......................................................................................................... 42 CIRCUIT DIAGRAM...................................................................................................... 43 HEATING CYCLE TROUBLESHOOTING........................................................................................ 55 FAN CONTROL KNOB (FAN SWITCH)........................................................................................ 56 BLOWER MOTOR DOES NOT RUN........................................................................................ 57 BLOWER MOTOR DOES NOT RUN IN CERTAIN POSITION.................................................................... 58 BLOWER MOTOR DOES NOT STOP AT "OFF" POSITION..................................................................... 58 CERAMIC HEATER....................................................................................................... 59 CERAMIC HEATER DOES NOT OPERATE.................................................................................. 60 CERAMIC HEATER DOES NOT STOP..................................................................................... 61 AIR CONDITIONING CYCLE TROUBLESHOOTING............................................................................... 62 CHECKING REFRIGERANT SYSTEM WITH MANIFOLD GAUGE.................................................................. 63 MAGNETIC CLUTCH...................................................................................................... 66 6VD1/6VE1 ENGINE................................................................................................. 66 4JG2 ENGINE...................................................................................................... 70 4JX1 ENGINE...................................................................................................... 73 CONDENSER FAN........................................................................................................ 76 CONDENSER FAN DOES NOT RUN....................................................................................... 77 CONDENSER FAN DOES NOT STOP...................................................................................... 78 COMPRESSOR TROUBLESHOOTING........................................................................................... 79 INDIVIDUAL INSPECTION................................................................................................ 80 MAIN DATA AND SPECIFICATIONS............................................................................................. 84 FIXING TORQUE............................................................................................................ 87 SPECIAL TOOLS............................................................................................................ 91 1A HEATING AND VENTILATION................................................................................................... 96 GENERAL DESCRIPTION...................................................................................................... 97 HEATER............................................................................................................... 97 CONTROL LEVER ASSEMBLY............................................................................................... 98 VENTILATION.......................................................................................................... 98 AIR SELECT KNOB...................................................................................................... 99 AIR SOURCE SELECT LEVER.............................................................................................. 99 FAN CONTROL KNOB..................................................................................................... 99 TEMPERATURE CONTROL KNOB............................................................................................. 99 CERAMIC HEATER....................................................................................................... 100 ON-VEHICLE SERVICE....................................................................................................... 101 HEATER UNIT.......................................................................................................... 101 HEATER CORE AND/OR MODE DOOR......................................................................................... 103 HEATER MODE CONTROL LINK UNIT........................................................................................ 105 HEATER TEMPERATURE CONTROL LINK UNIT................................................................................. 107 BLOWER ASSEMBLY...................................................................................................... 109 BLOWER LINK UNIT AND/OR MODE DOOR.................................................................................... 111 BLOWER MOTOR......................................................................................................... 113 REAR HEATER DUCT, DEFROSTER NOZZLE AND VENTILATION DUCT.............................................................. 115 CENTER AND/OR SIDE VENT.............................................................................................. 117 CONTROL LEVER ASSEMBLY AND/OR CONTROL CABLES......................................................................... 119 CONTROL PANEL ILLUMINATION BULB...................................................................................... 122 RESISTOR............................................................................................................. 123 CERAMIC HEATER AND/OR FULL HOT SWITCH................................................................................ 125 1B AIR CONDITIONING.......................................................................................................... 127 GENERAL DESCRIPTION...................................................................................................... 129 AIR CONDITIONING REFRIGERANT CYCLE CONSTRUCTION...................................................................... 129 COMPRESSOR........................................................................................................... 130 MAGNETIC CLUTCH...................................................................................................... 131 DUAL PRESSURE SWITCH................................................................................................. 132 TRIPLE PRESSURE SWITCH............................................................................................... 132 EXPANSION VALVE...................................................................................................... 132 EVAPORATOR........................................................................................................... 133 ELECTRONIC THERMOSTAT................................................................................................ 133 REFRIGERANT LINE..................................................................................................... 133 SERVICE CHARGE VALVES................................................................................................ 133 AIR CONDITIONING PARTS............................................................................................... 134 ON-VEHICLE SERVICE....................................................................................................... 139 PRECAUTIONS FOR REPLACEMENT OR REPAIR OF AIR CONDITIONING PARTS...................................................... 139 Compressor Assembly and Associated Parts............................................................................. 149 CONDENSER ASSEMBLY (LHD V6 WITHOUT CONDENSER FAN).................................................................... 159 CONDENSER FAN MOTOR.................................................................................................. 161 RECEIVER/DRIER....................................................................................................... 163 PRESSURE SWITCH...................................................................................................... 165 EVAPORATOR ASSEMBLY.................................................................................................. 168 EVAPORATOR CORE AND/OR EXPANSION VALVE............................................................................... 170 ELECTRONIC THERMOSTAT................................................................................................ 173 A/C SWITCH AND ILLUMINATION BULB..................................................................................... 174 REFRIGERANT LINE..................................................................................................... 175 REAR COOLER PARTS.................................................................................................... 177 FULL AUTOMATIC AIR CONDITIONING SYSTEM................................................................................... 186 GENERAL DESCRIPTION...................................................................................................... 186 Full Automatic Air Conditioner Parts Configuration................................................................... 186 CIRCUIT DIAGRAM...................................................................................................... 188 FUNCTIONS AND FEATURES............................................................................................... 200 FULL AUTOMATIC AIR CONDITIONER BLOCK DIAGRAM......................................................................... 201 AIR CONDITIONING PARTS............................................................................................... 202 Control Panel Layout................................................................................................. 206 Air Control Functions................................................................................................ 207 OPERATION AND FUNCTIONS OF CONTROL PANEL SWITCHES.................................................................... 208 OVERVIEW OF CONSTRUCTION, MOVEMENT AND CONTROL OF MAJOR PARTS OF FULL AUTOMATIC AIR CONDITIONER SYSTEM............... 210 OVERVIEW OF AUTOMATIC CONTROL OF FULL AUTOMATIC AIR CONDITIONER...................................................... 214 TROUBLESHOOTING.......................................................................................................... 218 Troubleshooting, Its Overview and Procedures......................................................................... 218 Performance and Movement checklist for Automatic Air Conditioner Related Parts....................................... 221 TROUBLESHOOTING WITH SELF-DIAGNOSIS FUNCTION......................................................................... 223 INSPECTION BY FAILED LOCATION............................................................................................ 226 Inspection of the Sensors............................................................................................ 226 Inspection of the Intake Actuator System............................................................................. 230 Inspection of the Mix Actuator System................................................................................ 233 Inspection of the Mode Actuator System............................................................................... 236 Inspection of the Fan Motor System................................................................................... 239 Inspection of the Magnet Clutch System............................................................................... 244 Inspection of the Air Conditioner Room Temperature Setup System...................................................... 249 INDIVIDUAL INSPECTION................................................................................................ 250 ON-VEHICLE SERVICE....................................................................................................... 252 Power Transistor..................................................................................................... 252 Automatic Heater/Air Conditioner Control Unit........................................................................ 252 In Car Sensor........................................................................................................ 253 Ambient Sensor....................................................................................................... 253 Sun Sensor........................................................................................................... 254 Electronic Thermostat................................................................................................ 254 Mode Actuator........................................................................................................ 255 MIX Actuator......................................................................................................... 255 Intake Actuator...................................................................................................... 256 1D COMPRESSOR OVERHAUL....................................................................................................... 257 GENERAL DESCRIPTION...................................................................................................... 258 GENERAL INFORMATION...................................................................................................... 260 COMPRESSOR OIL....................................................................................................... 260 SERVICE PROCEDURE........................................................................................................ 262 DKV-14D TYPE COMPRESSOR.............................................................................................. 262 DKS-15CH TYPE COMPRESSOR............................................................................................. 266 HD6 TYPE COMPRESSOR.................................................................................................. 274 Sec.2 SERVICE INFORMATION........................................................................................................ 283 00 SERVICE INFORMATION....................................................................................................... 283 TROUBLESHOOTING.......................................................................................................... 285 GENERAL INFORMATION.................................................................................................. 286 GENERAL TROUBLESHOOTING.............................................................................................. 286 POWER STEERING SYSTEM................................................................................................ 289 POWER STEERING PUMP.................................................................................................. 290 STEERING COLUMN...................................................................................................... 291 MAIN DATA AND SPECIFICATIONS............................................................................................. 293 SERVICE STANDARD......................................................................................................... 294 SERVICING................................................................................................................ 295 FIXING TORQUE............................................................................................................ 297 SPECIAL TOOLS............................................................................................................ 301 2A FRONT END ALIGNMENT....................................................................................................... 303 GENERAL DESCRIPTION...................................................................................................... 304 DEFINITION OF TERMS.................................................................................................. 304 ON-VEHICLE SERVICE....................................................................................................... 305 INSPECTION........................................................................................................... 305 TRIM HEIGHT ADJUSTMENT............................................................................................... 305 CASTER ADJUSTMENT.................................................................................................... 306 CAMBER ADJUSTMENT.................................................................................................... 306 TOE-IN ADJUSTMENT.................................................................................................... 307 MAXIMUM STEERING ANGLE ADJUSTMENT.................................................................................... 307 Sec.3 SUSPENSION................................................................................................................. 389 3C FRONT SUSPENSION.......................................................................................................... 389 GENERAL DESCRIPTION...................................................................................................... 390 ON-VEHICLE SERVICE....................................................................................................... 391 SHOCK ABSORBER....................................................................................................... 391 STABILIZER BAR....................................................................................................... 393 TORSION BAR.......................................................................................................... 395 KNUCKLE.............................................................................................................. 398 UPPER CONTROL ARM.................................................................................................... 402 LOWER CONTROL ARM.................................................................................................... 406 UPPER BALL JOINT..................................................................................................... 410 LOWER BALL JOINT..................................................................................................... 413 3D REAR SUSPENSION; COIL SPRING.............................................................................................. 416 GENERAL DESCRIPTION...................................................................................................... 417 ON-VEHICLE SERVICE....................................................................................................... 418 COIL SPRING.......................................................................................................... 418 SHOCK ABSORBER....................................................................................................... 421 TRAILING LINK........................................................................................................ 423 CENTER LINK.......................................................................................................... 425 LATERAL ROD.......................................................................................................... 427 STABILIZER BAR....................................................................................................... 430 3E WHEELS AND TIRES.......................................................................................................... 432 GENERAL DESCRIPTION...................................................................................................... 433 ON-VEHICLE SERVICE....................................................................................................... 434 WHEELS............................................................................................................... 434 UNIT REPAIR.............................................................................................................. 435 TIRES................................................................................................................ 435 WHEELS............................................................................................................... 436 GENERAL BALANCE PROCEDURE............................................................................................ 436 BALANCING WHEEL AND TIRE............................................................................................. 437 Sec.4 DRIVELINE/AXLE............................................................................................................. 438 4A1 DIFFERENTIAL (FRONT)..................................................................................................... 438 Service Precaution....................................................................................................... 438 Front Drive Axle......................................................................................................... 439 Diagnosis............................................................................................................ 439 Pinion Shaft Oil Seal.................................................................................................... 440 Pinion Shaft Oil Seal and Associated Parts........................................................................... 440 Removal.............................................................................................................. 440 Inspection and Repair................................................................................................ 441 Installation......................................................................................................... 441 Front Drive Axle Assembly................................................................................................ 442 Front Drive Axle Assembly and Associated Parts....................................................................... 442 Removal.............................................................................................................. 442 Installation......................................................................................................... 444 Differential Assembly.................................................................................................... 446 Disassembled View.................................................................................................... 446 Disassembly.......................................................................................................... 446 Reassembly........................................................................................................... 449 Differential Cage Assembly............................................................................................... 458 Disassembled View.................................................................................................... 458 Disassembly.......................................................................................................... 458 Inspection and Repair................................................................................................ 459 Reassembly........................................................................................................... 460 Main Data and Specifications......................................................................................... 462 Special Tools........................................................................................................ 465 4A2A DIFFERENTIAL (Rear 220mm)............................................................................................... 468 Service Precaution....................................................................................................... 468 General Description...................................................................................................... 469 Diagnosis................................................................................................................ 470 Axle Housing............................................................................................................. 471 Axle Housing and Associated Parts.................................................................................... 471 Removal.............................................................................................................. 471 Oil Seal Replacement................................................................................................. 472 Installation......................................................................................................... 472 Pinion Oil Seal.......................................................................................................... 473 Pinion Oil Seal and Associated Parts................................................................................. 473 Removal.............................................................................................................. 473 Inspection and Repair................................................................................................ 474 Installation......................................................................................................... 474 Differential Assembly.................................................................................................... 475 Differential Assembly and Associated Parts........................................................................... 475 Removal.............................................................................................................. 475 Installation......................................................................................................... 476 Disassembled View.................................................................................................... 477 Disassembly.......................................................................................................... 478 Reassembly........................................................................................................... 480 Differential Cage Assembly............................................................................................... 488 Disassembled View.................................................................................................... 488 Disassembly.......................................................................................................... 488 Inspection and Repair................................................................................................ 489 Reassembly........................................................................................................... 490 Limited Slip Differential................................................................................................ 492 Disassembled View.................................................................................................... 492 Disassembly.......................................................................................................... 493 Inspection and Repair................................................................................................ 493 Reassembly........................................................................................................... 495 Main Data and Specifications......................................................................................... 499 Special Tools........................................................................................................ 501 4A2B DIFFERENTIAL (REAR 244mm)............................................................................................... 504 Service Precaution....................................................................................................... 504 General Description...................................................................................................... 505 Diagnosis................................................................................................................ 506 Axle Housing............................................................................................................. 507 Axle Housing and Associated Parts.................................................................................... 507 Removal.............................................................................................................. 507 Oil Seal Replacement................................................................................................. 508 Installation......................................................................................................... 508 Pinion Oil Seal.......................................................................................................... 509 Pinion Oil Seal and Associated Parts................................................................................. 509 Removal.............................................................................................................. 509 Inspection and Repair................................................................................................ 510 Installation......................................................................................................... 510 Differential Assembly.................................................................................................... 511 Differential Assembly and Associated Parts........................................................................... 511 Removal.............................................................................................................. 511 Installation......................................................................................................... 512 Disassembled View.................................................................................................... 513 Disassembly.......................................................................................................... 514 Reassembly........................................................................................................... 516 Differential Cage Assembly............................................................................................... 523 Disassembled View.................................................................................................... 523 Disassembly.......................................................................................................... 524 Inspection and Repair................................................................................................ 524 Reassembly........................................................................................................... 524 Locking Differential Assembly............................................................................................ 526 Disassembled View.................................................................................................... 526 Disassembly.......................................................................................................... 526 Inspection and Repair................................................................................................ 528 Reassembly........................................................................................................... 528 Main Data and Specifications............................................................................................. 530 Special Tools............................................................................................................ 532 4B1 DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY).............................................................................. 534 Service Precaution....................................................................................................... 534 Shift on the Fly System (Lever Type)..................................................................................... 535 Outline of Shift on the Fly System (Lever Type)...................................................................... 535 Shift on the Fly Vacuum Piping and Electric Equipment (For Lever Control Type)........................................... 536 Vacuum Piping Diagram................................................................................................ 536 Inspection and Repair................................................................................................ 537 Shift on the Fly System (Push Button Type)............................................................................... 540 Outline of Shift on the Fly System (Push Button Type)................................................................ 540 Functions of Indicator Lamp.......................................................................................... 544 Diagnosis............................................................................................................ 544 Front Axle Diagnosis................................................................................................. 563 Shift on the Fly Vacuum Piping and Electric Equipment (For Push Button Type)............................................. 565 Vacuum Piping Diagram................................................................................................ 565 Inspection and Repair................................................................................................ 566 4WD Control Unit (For Push Button Type).................................................................................. 569 4WD Control Unit Associated Parts.................................................................................... 569 Removal.............................................................................................................. 570 Installation......................................................................................................... 570 4B2 DRIVELINE CONTROL SYSTEM (TOD)........................................................................................... 572 Service Precaution....................................................................................................... 572 General Description...................................................................................................... 573 System Components........................................................................................................ 575 Parts Location....................................................................................................... 575 Functions of Indicator Lamp.............................................................................................. 579 Diagnosis................................................................................................................ 583 Basic Diagnostic Flow Chart.............................................................................................. 587 Parts Location........................................................................................................... 588 Circuit Diagram.......................................................................................................... 589 Connector List........................................................................................................... 592 Checking Failed Pin...................................................................................................... 594 Checking Failed TOD Control Unit Pin..................................................................................... 597 Diagnostic Trouble Codes................................................................................................. 601 Diagnosis from Trouble Codes............................................................................................. 602 Trouble Diagnosis Depending on The Status of TOD Indicator............................................................... 629 Diagnosis from Symptom................................................................................................... 657 4C DRIVE SHAFT SYSTEM........................................................................................................ 667 Service Precaution....................................................................................................... 668 General Description...................................................................................................... 668 Diagnosis................................................................................................................ 669 Rear Axle Shaft.......................................................................................................... 670 Rear Axle Shaft and Associated Parts................................................................................. 670 Removal.............................................................................................................. 670 Inspection and Repair................................................................................................ 671 Oil Seal Replacement................................................................................................. 672 Installation......................................................................................................... 672 Special Tools............................................................................................................ 674 Front Hub and Disc (with Shift on the Fly)............................................................................... 675 Disassembled View.................................................................................................... 675 Disassembly.......................................................................................................... 675 Inspection and Repair................................................................................................ 676 Reassembly........................................................................................................... 677 Front Hub and Disc with Manual Locking Hub............................................................................... 680 Disassembled View.................................................................................................... 680 Disassembly.......................................................................................................... 680 Inspection and Repair................................................................................................ 682 Reassembly........................................................................................................... 682 Main Data and Specifications............................................................................................. 686 Special Tools............................................................................................................ 687 Front Drive Shaft Joint.................................................................................................. 688 Front Drive Shaft Joints Replacement................................................................................. 688 Front Axle Drive Shaft................................................................................................... 689 Front Axle Drive Shaft and Associated Parts.......................................................................... 689 Disassembly.......................................................................................................... 690 Inspection and Repair................................................................................................ 691 Bushing Replacement.................................................................................................. 691 Reassembly........................................................................................................... 692 Shift On The Fly System.................................................................................................. 694 Shift On The Fly System and Associated Parts......................................................................... 694 Disassembly.......................................................................................................... 694 Inspection and Repair................................................................................................ 696 Main Data and Specifications......................................................................................... 701 Special Tools........................................................................................................ 702 Front Propeller Shaft.................................................................................................... 703 General Description...................................................................................................... 703 Front Propeller Shaft and Associated Parts........................................................................... 704 Removal.............................................................................................................. 704 Installation......................................................................................................... 705 Disassembly (Except TOD 4×4)......................................................................................... 706 Universal Joint Disassembly.......................................................................................... 707 Inspection and Repair................................................................................................ 708 Universal Joint Reassembly........................................................................................... 711 Reassembly (Except TOD 4×4).......................................................................................... 712 Main Data and Specifications......................................................................................... 713 Rear Propeller Shaft..................................................................................................... 714 General Description...................................................................................................... 714 Rear Propeller Shaft and Associated Parts............................................................................ 714 Removal.............................................................................................................. 715 Installation......................................................................................................... 715 Disassembly.......................................................................................................... 716 Universal Joint Disassembly.......................................................................................... 717 Inspection and Repair................................................................................................ 718 Universal Joint Reassembly........................................................................................... 719 Reassembly........................................................................................................... 720 Main Data and Specifications......................................................................................... 721 4D1 TRANSFER CASE (STANDARD TYPE)............................................................................................ 722 Service Precaution....................................................................................................... 722 General Description...................................................................................................... 723 Transfer Rear Oil Seal................................................................................................... 729 Removal.............................................................................................................. 729 Installation......................................................................................................... 729 Transfer Case Assembly................................................................................................... 730 Removal.............................................................................................................. 730 Installation......................................................................................................... 731 Transfer Rear Cover Assembly (4WD Switch Model).......................................................................... 732 Transfer Rear Cover Assembly and Associated Parts........................................................................ 732 Removal.............................................................................................................. 733 Installation......................................................................................................... 734 Disassembly.......................................................................................................... 737 Inspection and Repair................................................................................................ 738 Reassembly........................................................................................................... 738 Transfer Rear Cover Assembly (Except 4WD Switch Model)................................................................... 740 Transfer Rear Cover Assembly and Associated Parts.................................................................... 740 Removal.............................................................................................................. 741 Installation......................................................................................................... 741 Disassembly.......................................................................................................... 744 Inspection and Repair................................................................................................ 745 Reassembly........................................................................................................... 745 Detent, Shift Arm, and Interlock Pin..................................................................................... 747 Disassembled View.................................................................................................... 747 Disassembly.......................................................................................................... 747 Inspection and Repair................................................................................................ 749 Reassembly........................................................................................................... 749 Transfer Case Assembly................................................................................................... 751 Disassembled View.................................................................................................... 751 Disassembly.......................................................................................................... 752 Inspection and Repair................................................................................................ 754 Reassembly........................................................................................................... 758 Main Data and Specifications............................................................................................. 764 Special Tools............................................................................................................ 767 4D2 TRANSFER CASE (TOD)...................................................................................................... 768 Service Precaution....................................................................................................... 768 Transfer Case Assembly................................................................................................... 769 Removal.............................................................................................................. 769 Installation......................................................................................................... 770 Transfer Rear Oil Seal................................................................................................... 772 Transfer Rear Oil Seal and Associated Parts.......................................................................... 772 Removal.............................................................................................................. 772 Installation......................................................................................................... 772 TOD ECU.................................................................................................................. 774 Removal.............................................................................................................. 774 Installation......................................................................................................... 774 Unit Repair.............................................................................................................. 775 Inspection........................................................................................................... 775 Transfer Case............................................................................................................ 776 Disassembled View.................................................................................................... 776 Disassembly.......................................................................................................... 776 Reassembly........................................................................................................... 777 Transfer Cover Assembly.................................................................................................. 779 Disassembled View.................................................................................................... 779 Disassembly.......................................................................................................... 779 Reassembly........................................................................................................... 781 Transfer Case Assembly Clutch Pack and Clutch Cam........................................................................ 783 Disassembled View.................................................................................................... 783 Disassembly.......................................................................................................... 783 Sprocket and Mechanical Lock............................................................................................. 785 Disassembled View.................................................................................................... 785 Disassembly.......................................................................................................... 785 Output Shafts and Shift Control Shaft.................................................................................... 787 Disassembled View.................................................................................................... 787 Disassembly.......................................................................................................... 788 Transfer Case............................................................................................................ 790 Disassembled View.................................................................................................... 790 Disassembly.......................................................................................................... 791 Inspection and Repair................................................................................................ 793 Transfer Case............................................................................................................ 797 Disassembled View.................................................................................................... 797 Reassembly........................................................................................................... 797 Output Shafts and Shift Control Shaft.................................................................................... 801 Disassembled View.................................................................................................... 801 Reassembly........................................................................................................... 801 Sprocket and Mechanical Lock............................................................................................. 804 Disassembled View.................................................................................................... 804 Reassembly........................................................................................................... 804 Clutch Pack and Clutch Cam............................................................................................... 806 Disassembled View.................................................................................................... 806 Reassembly........................................................................................................... 806 Main Data and Specifications............................................................................................. 808 Special Tools............................................................................................................ 810 Sec.5 BRAKES..................................................................................................................... 811 5A BRAKE CONTROL SYSTEM...................................................................................................... 811 Service Precaution....................................................................................................... 812 General Description...................................................................................................... 813 System Components.................................................................................................... 813 Electronic Hydraulic Control Unit (EHCU)............................................................................. 813 ABS Warning Light.................................................................................................... 814 Wheel Speed Sensor................................................................................................... 814 G-Sensor............................................................................................................. 814 Normal and Anti-lock Braking......................................................................................... 814 Brake Pedal Travel................................................................................................... 814 Acronyms and Abbreviations........................................................................................... 814 General Diagnosis........................................................................................................ 815 General Information.................................................................................................. 815 ABS Service Precautions.............................................................................................. 815 Computer System Service Precautions.................................................................................. 815 General Service Precautions.......................................................................................... 815 Note on Intermittents................................................................................................ 815 Test Driving ABS Complaint Vehicles.................................................................................. 816 “ABS” Warning Light.................................................................................................. 816 Normal Operation..................................................................................................... 816 Basic Diagnostic Flow Chart.......................................................................................... 816 Basic Inspection Procedure........................................................................................... 817 Tech 2 Scan Tool..................................................................................................... 818 Getting Started...................................................................................................... 819 Operating Procedure.................................................................................................. 820 Data List............................................................................................................ 821 EHCU Connector Pin-out Checks........................................................................................ 822 Circuit Diagram (LHD model / 6VD1 and 4JG2).......................................................................... 823 Circuit Diagram (LHD model / 4JG2)................................................................................... 824 Circuit Diagram (LHD model / 4JG2)................................................................................... 825 Circuit Diagram (LHD model / 6VD1)................................................................................... 826 Circuit Diagram (LHD model / 6VD1)................................................................................... 827 Connector List (LHD model)........................................................................................... 828 Part Location (LHD model)............................................................................................ 830 Circuit Diagram (RHD model / 6VD1 and 4JG2).......................................................................... 831 Circuit Diagram (RHD model / 4JG2)................................................................................... 832 Circuit Diagram (RHD model / 4JG2)................................................................................... 833 Circuit Diagram (RHD model / 6VD1)................................................................................... 834 Circuit Diagram (RHD model / 6VD1)................................................................................... 835 Circuit Diagram (RHD model / 6VE1 and 4JX1).......................................................................... 836 Circuit Diagram (RHD model / 4JX1)................................................................................... 837 Circuit Diagram (RHD model / 4JX1)................................................................................... 838 Circuit Diagram (RHD model / 6VE1)................................................................................... 839 Circuit Diagram (RHD model / 6VE1)................................................................................... 840 Connector List (RHD model)........................................................................................... 841 Part Location (RHD model)............................................................................................ 844 Symptom Diagnosis........................................................................................................ 845 Chart A–1 ABS Works Frequently But Vehicle Does Not Decelerate....................................................... 845 Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)......................................... 846 Chart A-2 Uneven Braking Occurs While ABS Works...................................................................... 846 Chart A-3, TA-3 The Wheels Are Locked................................................................................ 846 Chart A-4 Brake Pedal Feed Is Abnormal............................................................................... 847 Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................. 848 Diagnostic Trouble Codes................................................................................................. 849 Diagnosis By “ABS” Warning Light Illumination Pattern.................................................................... 850 Diagnostic Trouble Codes (DTCs)...................................................................................... 850 Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated......... 853 Chart B-2 EHCU Abnormality (DTC 14).................................................................................. 853 Chart B-3 Power Voltage Drop (DTC 15)................................................................................ 854 Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)............................................................ 854 Chart B-5 G-Sensor Circuit (DTC 21).................................................................................. 855 Chart B-6 Abnormal Transmission Input (DTC 23)....................................................................... 856 Chart B-7 Transfer Monitor (DTC 24).................................................................................. 857 Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32)........................................................... 857 Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35)........................................................... 857 Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41).......................................................... 858 Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42)............................................................... 858 Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43).......................................................... 858 Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44)............................................................... 859 Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45)........................................................ 859 Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)............................................................. 859 Chart B-16 FL Speed Sensor Disconnection (DTC 51).................................................................... 860 Chart B-17 FR Speed Sensor Disconnection (DTC 52).................................................................... 860 Chart B-18 RL Speed Sensor Disconnection (DTC 53).................................................................... 861 Chart B-19 RR Speed Sensor Disconnection (DTC 54).................................................................... 861 Chart B-20 FL Speed Sensor Short Circuit (DTC 61).................................................................... 862 Chart B-21 FR Speed Sensor Short Circuit (DTC 62).................................................................... 863 Chart B-22 RL Speed Sensor Short Circuit (DTC 63).................................................................... 864 Chart B-23 RR Speed Sensor Short Circuit (DTC 64).................................................................... 865 Chart B-24 Sensor Signal Input Abnormality (DTC 65).................................................................. 866 Sensor Signal Abnormality Criteria using TECH 2...................................................................... 866 Unit Inspection Procedure................................................................................................ 867 Chart C-1-1 FL Sensor Output Inspection Procedure.................................................................... 867 Chart C-1-2 FR Sensor Output Inspection Procedure.................................................................... 868 Chart C-1-3 RL Sensor Output Inspection Procedure.................................................................... 868 Chart C-1-4 RR Sensor Output Inspection Procedure.................................................................... 869 Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)........................................................... 869 Chart C-2 Transmission Input Inspection Procedure.................................................................... 870 Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2)...................................................... 871 Special Tools............................................................................................................ 872 5B ANTI-LOCK BRAKE SYSTEM.................................................................................................... 873 Service Precaution....................................................................................................... 873 Electronic Hydraulic Control Unit........................................................................................ 874 Electronic Hydraulic Control Unit and Associated Parts............................................................... 874 Removal.............................................................................................................. 874 Installation......................................................................................................... 874
G-Sensor................................................................................................................. 875 Removal.............................................................................................................. 875 Inspection and Repair................................................................................................ 875 Installation......................................................................................................... 875 Front Wheel Speed Sensor................................................................................................. 876 Front Wheel Speed Sensor and Associated Parts........................................................................ 876 Removal.............................................................................................................. 876 Inspection and Repair................................................................................................ 877 Installation......................................................................................................... 877 Rear Wheel Speed Sensor.................................................................................................. 878 Rear Wheel Speed Sensor and Associated Parts......................................................................... 878 Removal.............................................................................................................. 878 Inspection and Repair................................................................................................ 878 Installation......................................................................................................... 878 5C POWER ASSISTED BRAKE SYSTEM............................................................................................... 879 SERVICE PRECAUTION....................................................................................................... 880 BRAKE SYSTEM DIAGNOSIS................................................................................................... 881 TROUBLESHOOTING.......................................................................................................... 883 MAIN DATA AND SPECIFICATIONS............................................................................................. 885 SERVICE STANDARD......................................................................................................... 886 SERVICING................................................................................................................ 887 FIXING TORQUE............................................................................................................ 896 SPECIAL TOOLS............................................................................................................ 899 GENERAL DESCRIPTION...................................................................................................... 900 MASTER CYLINDER...................................................................................................... 900 VACUUM BOOSTER....................................................................................................... 901 DISC BRAKES.......................................................................................................... 902 ON-VEHICLE SERVICE....................................................................................................... 903 BRAKE HOSE REPLACEMENT............................................................................................... 903 BRAKE PIPE REPLACEMENT............................................................................................... 905 P & B VALVE.......................................................................................................... 906 P & B VALVE REPLACEMENT.............................................................................................. 907 LOAD SENSING PROPORTIONING VALVE (LSPV).............................................................................. 908 BRAKE PEDAL REPLACEMENT.............................................................................................. 912 STOPLIGHT SWITCH REPLACEMENT......................................................................................... 914 FLUID RESERVOIR TANK................................................................................................. 916 MASATER CYLINDER ASSEMBLY............................................................................................ 917 VACUUM BOOSTER ASSEMBLY.............................................................................................. 919 EXTERIOR COMPONENTS.................................................................................................. 922 FRONT DISC BRAKE..................................................................................................... 925 BRAKE PADS REPLACEMENT........................................................................................... 925 CALIPER REPLACEMENT.............................................................................................. 928 REBUILDING THE CALIPER........................................................................................... 931 REAR DISC BRAKE...................................................................................................... 934 BRAKE PADS REPLACEMENT........................................................................................... 934 CALIPER REPLACEMENT.............................................................................................. 937 REBUILDING THE CALIPER........................................................................................... 940 UNIT REPAIR.......................................................................................................... 943 MASTER CYLINDER.................................................................................................. 943 VACUUM BOOSTER................................................................................................... 945 5D PARKING BRAKES............................................................................................................ 946 SERVICE PRECAUTION....................................................................................................... 946 MAIN DATA AND SPECIFICATIONS............................................................................................. 947 SERVICE STANDARD......................................................................................................... 947 SERVICING................................................................................................................ 948 FIXING TORQUE............................................................................................................ 950 GENERAL DESCRIPTION...................................................................................................... 951 ON-VEHICLE SERVICE....................................................................................................... 952 PARKING BRAKE LEVER REPLACEMENT...................................................................................... 952 PARKING BRAKE CABLE.................................................................................................. 954 Sec.6 ENGINE(6VD1/6VE1).......................................................................................................... 957 6A ENGINE MECHANICAL......................................................................................................... 957 Service Precaution....................................................................................................... 958 General Description...................................................................................................... 959 Engine Diagnosis......................................................................................................... 960 Cylinder Head Cover LH................................................................................................... 974 Removal.............................................................................................................. 974 Installation......................................................................................................... 975 Cylinder Head Cover RH................................................................................................... 977 Removal.............................................................................................................. 977 Installation......................................................................................................... 978 Common Chamber........................................................................................................... 980 Removal.............................................................................................................. 980 Installation......................................................................................................... 980 Exhaust Manifold LH...................................................................................................... 982 Removal.............................................................................................................. 982 Installation......................................................................................................... 982 Exhaust Manifold RH...................................................................................................... 983 Removal.............................................................................................................. 983 Installation......................................................................................................... 983 Crankshaft Pulley........................................................................................................ 984 Removal.............................................................................................................. 984 Installation......................................................................................................... 984 Timing Belt.............................................................................................................. 985 Removal.............................................................................................................. 985 Installation......................................................................................................... 986 Camshaft................................................................................................................. 989 Removal.............................................................................................................. 989 Installation......................................................................................................... 989 Cylinder Head............................................................................................................ 993 Removal.............................................................................................................. 993 Installation......................................................................................................... 993 Valve Stem Oil Controller , Valve Spring and Valve Guide................................................................. 995 Removal.............................................................................................................. 995 Installation......................................................................................................... 995 Piston, Piston Ring and Connecting Rod................................................................................... 996 Removal.............................................................................................................. 996 Installation......................................................................................................... 997 Crankshaft and Main Bearings............................................................................................. 998 Removal.............................................................................................................. 998 Installation......................................................................................................... 999 Rear Oil Seal............................................................................................................ 1003 Removal.............................................................................................................. 1003 Installation......................................................................................................... 1003 Engine Assembly.......................................................................................................... 1004 Removal.............................................................................................................. 1004 Installation......................................................................................................... 1004 Cylinder Head............................................................................................................ 1008 Cylinder Head and Associated Parts................................................................................... 1008 Disassembly.......................................................................................................... 1008 Clean................................................................................................................ 1009 Inspection and Repair................................................................................................ 1009 Reassembly........................................................................................................... 1009 Valve Spring, Oil Controller, Valve, Valve Guide......................................................................... 1012 Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts................................................ 1012 Disassembly.......................................................................................................... 1012 Inspection and Repair................................................................................................ 1013 Reassembly........................................................................................................... 1016 Valve Clearance Adjustments.............................................................................................. 1017 Camshaft................................................................................................................. 1019 Camshaft and Associated Parts........................................................................................ 1019 Disassembly.......................................................................................................... 1019 Inspection and Repair................................................................................................ 1020 Reassembly........................................................................................................... 1022 Crankshaft............................................................................................................... 1025 Crankshaft and Associated Parts...................................................................................... 1025 Disassembly.......................................................................................................... 1025 Inspection and Repair................................................................................................ 1026 Inspection and Repair................................................................................................ 1027 Reassembly........................................................................................................... 1029 Piston and Connecting Rod................................................................................................ 1033 Piston, Connecting Rod and Associate Parts........................................................................... 1033 Disassembly.......................................................................................................... 1033 Inspection and Repair................................................................................................ 1034 Reassembly........................................................................................................... 1038 Cylinder Block........................................................................................................... 1041 Cylinder Block and Associated Parts.................................................................................. 1041 Disassembly.......................................................................................................... 1041 Inspection and Repair................................................................................................ 1042 Reassembly........................................................................................................... 1043 Main Data and Specification.............................................................................................. 1046 Special Tool............................................................................................................. 1052 6B ENGINE COOLING............................................................................................................ 1054 Service Precaution....................................................................................................... 1054 General Description...................................................................................................... 1055 Diagnosis................................................................................................................ 1058 Draining and Refilling Cooling System.................................................................................... 1059 Water Pump............................................................................................................... 1060 Water Pump and Associated Parts...................................................................................... 1060 Removal.............................................................................................................. 1060 Inspection........................................................................................................... 1060 Installation......................................................................................................... 1060 Thermostat............................................................................................................... 1061 Thermostat and Associated Parts...................................................................................... 1061 Removal.............................................................................................................. 1061 Inspection........................................................................................................... 1061 Installation......................................................................................................... 1061 Radiator................................................................................................................. 1062 Radiator and Associated Parts........................................................................................ 1062 Removal.............................................................................................................. 1062 Inspection........................................................................................................... 1063 Installation......................................................................................................... 1064 Drive Belt and Cooling Fan............................................................................................... 1065 Drive Belt and Associated Parts...................................................................................... 1065 Inspection........................................................................................................... 1065 Installation......................................................................................................... 1065 Main Data and Specifications............................................................................................. 1066 Special Tool............................................................................................................. 1067 6C ENGINE FUEL............................................................................................................... 1068 Service Precaution....................................................................................................... 1068 General Description...................................................................................................... 1069 Fuel Metering............................................................................................................ 1070 Fuel Filter.............................................................................................................. 1071 Fuel Filter and Associated Parts..................................................................................... 1071 Removal.............................................................................................................. 1071 Inspection........................................................................................................... 1071 Installation......................................................................................................... 1072 Inspection........................................................................................................... 1072 In–Tank Fuel Filter.................................................................................................. 1072 Fuel Pump Flow Test.................................................................................................. 1072 Fuel Pump................................................................................................................ 1073 Fuel Pump and Associated Parts....................................................................................... 1073 Removal.............................................................................................................. 1073 Installation......................................................................................................... 1073 Fuel Pump Relay.......................................................................................................... 1074 General Description...................................................................................................... 1074 Fuel Tank................................................................................................................ 1074 Fuel Tank and Associated Parts....................................................................................... 1074 Removal.............................................................................................................. 1074 Installation......................................................................................................... 1075 Fuel Tube / Quick – Connect Fittings..................................................................................... 1075 Precautions.......................................................................................................... 1075 Cautions During Work................................................................................................. 1075 Removal.............................................................................................................. 1075 Reuse of Quick–Connector................................................................................................. 1077 Assembling Advice........................................................................................................ 1077 Fuel Gauge Unit.......................................................................................................... 1078 Fuel Gauge Unit and Associated Parts................................................................................. 1078 Removal.............................................................................................................. 1078 Installation......................................................................................................... 1078 Fuel Filler Cap.......................................................................................................... 1079 General Description...................................................................................................... 1079 Inspection........................................................................................................... 1079 Main Data and Specifications............................................................................................. 1079 6D1 ENGINE ELECTRICAL........................................................................................................ 1080 Service Precaution....................................................................................................... 1080 Battery.................................................................................................................. 1081 General Description.................................................................................................. 1081 Diagnosis............................................................................................................ 1081 Battery Charging..................................................................................................... 1082 Jump Starting........................................................................................................ 1082 Battery Removal...................................................................................................... 1083 Battery Installation................................................................................................. 1083 Main Data and Specifications......................................................................................... 1084 6D2 IGNITION SYSTEM.......................................................................................................... 1086 Service Precaution....................................................................................................... 1086 General Description...................................................................................................... 1087 Diagnosis................................................................................................................ 1087 Ignition Coil............................................................................................................ 1088 Removal.............................................................................................................. 1088 Inspection and Repair................................................................................................ 1088 Installation......................................................................................................... 1088 Spark Plug............................................................................................................... 1089 Removal.............................................................................................................. 1089 Inspection and Repair................................................................................................ 1089 Installation......................................................................................................... 1089 Crankshaft Angle Sensor.................................................................................................. 1090 Removal.............................................................................................................. 1090 Installation......................................................................................................... 1090 Main Data and Specifications............................................................................................. 1091 6D3 STARTING AND CHARGING SYSTEM............................................................................................. 1092 Service Precaution....................................................................................................... 1092 Starting System.......................................................................................................... 1093 General Description...................................................................................................... 1093 Diagnosis................................................................................................................ 1095 Starter.................................................................................................................. 1096 Removal.............................................................................................................. 1096 Installation......................................................................................................... 1096 Disassembled View.................................................................................................... 1097 Disassembly.......................................................................................................... 1098 Inspection and Repair................................................................................................ 1100 Reassembly........................................................................................................... 1104 Main Data and Specifications......................................................................................... 1106 Charging System.......................................................................................................... 1109 General Description...................................................................................................... 1109 General On–Vehicle Inspection............................................................................................ 1109 Generator................................................................................................................ 1110 Removal.............................................................................................................. 1110 Inspection........................................................................................................... 1110 Installation......................................................................................................... 1110 Disassembled View.................................................................................................... 1111 Disassembly.......................................................................................................... 1112 Inspection and Repair................................................................................................ 1114 Reassembly........................................................................................................... 1115 Bench Test........................................................................................................... 1116 Main Data and Specifications......................................................................................... 1117 6E ENGINE DRIVEABILITY AND EMISSIONS......................................................................................... 1118 Specifications........................................................................................................... 1122 Tightening Specifications................................................................................................ 1122 Vehicle Type Specifications.............................................................................................. 1122 Diagrams and Schematics.................................................................................................. 1123 PCM Wiring Diagram (1 of 11)......................................................................................... 1123 PCM Wiring Diagram (2 of 11) For EC, THAILAND, SOUTH EAST ASIA, LATIN AMERICA, GULF, SAUDI, CHINA.................... 1124 PCM Wiring Diagram (3 of 11) For SOUTH AFRICA and EXP................................................................ 1125 PCM Wiring Diagram (4 of 11)......................................................................................... 1126 PCM Wiring Diagram (5 of 11)......................................................................................... 1127 PCM Wiring Diagram (6 of 11) For AUSTRALIA, THAILAND, SOUTH EAST ASIA, LATIN AMERICA, GULF, SAUDI, LATIN AMERICA..... 1128 PCM Wiring Diagram (7 of 11) For EC.................................................................................. 1129 PCM Wiring Diagram (8 of 11) For EXPORT and SOUTH AFRICA............................................................. 1130 PCM Wiring Diagram (9 of 11) Except EXP and SOUTH AFRICA............................................................. 1131 PCM Wiring Diagram (10 of 11) For EXPORT and SOUTH AFRICA............................................................ 1132 PCM Wiring Diagram (11 of 11)........................................................................................ 1133 PCM Pinouts.............................................................................................................. 1134 PCM Pinout Table, 32-Way Red Connector – Row “A”..................................................................... 1134 PCM Pinout Table, 32-Way Red Connector – Row “B”..................................................................... 1136 PCM Pinout Table, 32-Way White Connector – Row “C” (For EC).......................................................... 1137 PCM Pinout Table, 32-Way White Connector – Row “C” (For except EC)................................................... 1138 PCM Pinout Table, 32-Way White Connector ‐ Row “D” (For except EXPORT and SOUTH AFRICA).............................. 1139 PCM Pinout Table, 32-Way White Connector ‐ Row “D” (For EXPORT and SOUTH AFRICA)..................................... 1140 PCM Pinout Table, 32-Way Blue Connector ‐ Row “E” (For except EXPORT and SOUTH AFRICA)............................... 1141 PCM Pinout Table, 32-Way Blue Connector ‐ Row “E” (For EXPORT and SOUTH AFRICA)...................................... 1143 PCM Pinout Table, 32-Way Blue Connector ‐ Row “F”.................................................................... 1144 Component Locators....................................................................................................... 1145 Engine Component Locator (This illustration is based on RHD model.).................................................. 1145 Engine Component Locator Table....................................................................................... 1146 Engine Component Locator Table....................................................................................... 1148 Undercarriage Component Locator...................................................................................... 1149 Undercarriage Component Locator Table (Automatic Transmission)....................................................... 1149 Undercarriage Component Locator Table (Manual Transmission).......................................................... 1150 Fuse and Relay Panel (Underhood Electrical Center)................................................................... 1150 Sensors and Miscellaneous Component Locators......................................................................... 1151 Diagnosis................................................................................................................ 1154 Strategy-Based Diagnostics........................................................................................... 1154 Strategy-Based Diagnostics........................................................................................... 1154 DTC Stored........................................................................................................... 1154 No DTC............................................................................................................... 1154 No Matching Symptom.................................................................................................. 1154 Intermittents........................................................................................................ 1154 No Trouble Found..................................................................................................... 1154 Verifying Vehicle Repair............................................................................................. 1154 General Service Information.............................................................................................. 1155 OBD Serviceablity Issues............................................................................................. 1155 Maintenance Schedule................................................................................................. 1155 Visual / Physical Engine Compartment Inspection...................................................................... 1155 Basic Knowledge of Tools Required.................................................................................... 1155 Serial Data Communications............................................................................................... 1155 Class II Serial Data Communications.................................................................................. 1155 On-Board Diagnostic (OBD)................................................................................................ 1156 On-Board Diagnostic Tests............................................................................................ 1156 Comprehensive Component Monitor Diagnostic Operation................................................................. 1156 Common OBD Terms..................................................................................................... 1157 The Diagnostic Executive............................................................................................. 1157 DTC Types............................................................................................................ 1158 Verifying Vehicle Repair............................................................................................. 1159 Reading Diagnostic Trouble Codes Using A Tech 2...................................................................... 1159 Tech 2............................................................................................................... 1160 Tech 2 Features...................................................................................................... 1160 Getting Started...................................................................................................... 1161 Operating Procedure (For Example).................................................................................... 1161 DTC Modes............................................................................................................ 1162 DTC Information Mode................................................................................................. 1163 Injector Balance Test................................................................................................ 1163 EGR Control Test..................................................................................................... 1164 Idle Air Control System Test......................................................................................... 1165 Primary System-Based Diagnostic.......................................................................................... 1167 Primary System-Based Diagnostic...................................................................................... 1167 Fuel Control Heated Oxygen Sensor.................................................................................... 1167 HO2S Heater.......................................................................................................... 1167 Fuel Trim System Monitor Diagnostic Operation............................................................................ 1167 Fuel Trim System Monitor Diagnostic Operation........................................................................ 1167 Fuel Trim Cell Diagnostic Weights.................................................................................... 1167 On-Board Diagnostic (OBD) System Check................................................................................... 1168 A/C Clutch Control Circuit Diagnosis..................................................................................... 1171 Electronic Ignition System Diagnosis..................................................................................... 1177 Fuel Metering System Check............................................................................................... 1177 Idle Air Control (IAC) Valve............................................................................................. 1177 Fuel System Pressure Test................................................................................................ 1177 Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure............................................... 1177 Knock Sensor Diagnosis................................................................................................... 1182 Powertrain Control Module (PCM) Diagnosis................................................................................ 1182 Multiple PCM Information Sensor DTCS Set................................................................................. 1182 Exhaust Gas Recirculation (EGR) Diagnosis (For except EXPORT and SOUTH AFRICA)........................................... 1185 Engine Tech 2 Data Definitions and Ranges................................................................................ 1185 Typical Scan Data Values................................................................................................. 1187 No Malfunction Indicator Lamp (MIL)...................................................................................... 1191 Malfunction Indicator Lamp (MIL) “ON” Steady............................................................................. 1194 Engine Cranks But Will Not Run........................................................................................... 1196 Fuel System Electrical Test.............................................................................................. 1202 Fuel System Diagnosis.................................................................................................... 1205 Idle Air Control (IAC) System Check...................................................................................... 1210 Knock Sensor (KS) System Check (Engine Knock, Poor Performance, or Poor Economy)......................................... 1212 Exhaust Gas Recirculation (EGR) System Check............................................................................. 1214 Manifold Absolute Pressure (MAP) Output Check............................................................................ 1216 PCM Diagnostic Trouble Codes............................................................................................. 1218 Diagnostic Trouble Code (DTC) P0101 MAF System Performance............................................................... 1221 Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency..................................................... 1224 Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency.................................................... 1227 Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage....................................................... 1229 Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage...................................................... 1232 Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage....................................................... 1235 Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage...................................................... 1238 Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage....................................................... 1241 Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage...................................................... 1244 Diagnostic Trouble Code (DTC) P0121 TP System Performance................................................................ 1247 Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage........................................................ 1250 Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage....................................................... 1253 Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1............................................. 1256 Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1............................................ 1259 Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1................................... 1262 Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1............................................. 1265 Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1............................................ 1268 Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1......................................................... 1271 Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1......................................................... 1275 Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2......................................................... 1279 Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2......................................................... 1283 Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit........................................................... 1287 Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit........................................................... 1290 Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit........................................................... 1293 Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit........................................................... 1296 Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit........................................................... 1299 Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit........................................................... 1302 Diagnostic Trouble Code (DTC) P0325 KS Module Circuit.................................................................... 1305 Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit.................................................................... 1307 Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit......................................................... 1310 Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency..................................................... 1312 Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performance....................................................... 1315 Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low............................................................... 1319 Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit........................................................... 1323 Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit........................................................... 1326 Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit........................................................... 1329 Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit........................................................... 1332 Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit........................................................... 1335 Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit........................................................... 1338 Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error............................................................... 1341 Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck....................................................................... 1343 Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage...................................................................... 1345 Diagnostic Trouble Code (DTC) P0406 EGR High Voltage..................................................................... 1348 Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input................................................................ 1351 Diagnostic Trouble Code (DTC) P0562 System Voltage Low................................................................... 1354 Diagnostic Trouble Code (DTC) P0563 System Voltage High.................................................................. 1356 Diagnostic Trouble Code (DTC) P0601 PCM Memory........................................................................... 1357 Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1................................... 1358 Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration................................................. 1362 Diagnostic Trouble Code (DTC) P1380 ABS Rough Road ABS System Fault...................................................... 1365 Diagnostic Trouble Code (DTC) P1404 EGR Closed Stuck..................................................................... 1366 Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM................................................................... 1368 Diagnostic Trouble Code (DTC) P1509 IAC System High RPM.................................................................. 1371 Diagnostic Trouble Code (DTC) P1618 Serial Peripheral Interface (SPI) PCM Interprocessor Communication Error............. 1374 Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset................................................................. 1375 Diagnostic Trouble Code (DTC) P1640 Driver-1-Input High Voltage.......................................................... 1376 Symptom Diagnosis........................................................................................................ 1379 Default Matrix Table..................................................................................................... 1405 Camshaft Position (CMP) Sensor........................................................................................... 1408 Crankshaft Position (CKP) Sensor......................................................................................... 1409 Engine Coolant Temperature (ECT) Sensor.................................................................................. 1409 Heated Oxygen Sensor (HO2S).............................................................................................. 1410 Intake Air Temperature (IAT) Sensor...................................................................................... 1412 Knock Sensor (KS)........................................................................................................ 1413 Mass Air Flow (MAF) Sensor............................................................................................... 1414 Manifold Absolute Pressure (MAP) Sensor.................................................................................. 1414 Malfunction Indicator Lamp (MIL)......................................................................................... 1415 Powertrain Control Module (PCM).......................................................................................... 1415 EEPROM................................................................................................................... 1417 Power Steering Pressure (PSP) Switch..................................................................................... 1417 Throttle Position (TP) Sensor............................................................................................ 1418 Vehicle Speed Sensor (VSS)............................................................................................... 1419 Air Cleaner/Air Filter................................................................................................... 1420 Idle Air Control (IAC) Valve............................................................................................. 1421 Common Chamber........................................................................................................... 1422 Accelerator Cable Assembly............................................................................................... 1422 Accelerator Pedal Replacement............................................................................................ 1425 Fuel Filter Cap.......................................................................................................... 1427 Fuel Filter.............................................................................................................. 1427 Fuel Gauge Unit.......................................................................................................... 1430 Fuel Injectors........................................................................................................... 1431 Fuel Pressure Regulator.................................................................................................. 1432 Fuel Metering System..................................................................................................... 1434 Fuel Pump Assembly....................................................................................................... 1435 Fuel Pump Relay.......................................................................................................... 1436 Fuel Rail Assembly....................................................................................................... 1436 Fuel Tank................................................................................................................ 1438 Throttle Body (TB)....................................................................................................... 1440 Electronic Ignition System............................................................................................... 1441 Catalytic Converter...................................................................................................... 1442 Air Conditioning Relay................................................................................................... 1442 EVAP Canister Hoses...................................................................................................... 1443 EVAP Canister............................................................................................................ 1443 EVAP Canister Purge Solenoid............................................................................................. 1444 Fuel Tank Vent Valve..................................................................................................... 1445 Linear Exhaust Gas Recirculation (EGR) Valve............................................................................. 1445 Positive Crankcase Ventilation (PCV) Valve............................................................................... 1446 Wiring and Connectors.................................................................................................... 1447 PCM Connectors and Terminals............................................................................................. 1447 Wire Harness Repair: Twisted Shielded Cable.............................................................................. 1447 Twisted Leads............................................................................................................ 1448 Weather-Pack Connector................................................................................................... 1449 Com-Pack III............................................................................................................. 1450 Metri-Pack............................................................................................................... 1450 General Description...................................................................................................... 1452 General Description (PCM and Sensors).................................................................................... 1452 58X Reference PCM Input.............................................................................................. 1452 A/C Request Signal................................................................................................... 1452 Crankshaft Position (CKP) Sensor..................................................................................... 1452 Camshaft Position (CMP) Sensor and Signal............................................................................ 1452 Engine Coolant Temperature (ECT) Sensor.............................................................................. 1452 Electrically Erasable Programmable Read Only Memory (EEPROM)......................................................... 1453 Fuel Control Heated Oxygen Sensors................................................................................... 1453 Intake Air Temperature (IAT) Sensor.................................................................................. 1453 Knock Sensor......................................................................................................... 1454 Linear Exhaust Gas Recirculation (EGR) Control....................................................................... 1454 Mass Air Flow (MAF) Sensor........................................................................................... 1454 Manifold Absolute Pressure (MAP) Sensor.............................................................................. 1455 Powertrain Control Module (PCM)...................................................................................... 1455 PCM Function......................................................................................................... 1455 PCM Components....................................................................................................... 1456 PCM Voltage Description.............................................................................................. 1456 PCM Input/Outputs.................................................................................................... 1456 PCM Service Precautions.............................................................................................. 1456 Reprogramming The PCM................................................................................................ 1456 Throttle Position (TP) Sensor........................................................................................ 1456 Transmission Fluid Temperature (TFT) Sensor.......................................................................... 1457 Transmission Range Switch............................................................................................ 1457 Vehicle Speed Sensor (VSS)........................................................................................... 1457 Use of Circuit Testing Tools......................................................................................... 1457 Aftermarket Electrical and Vacuum Equipment.......................................................................... 1457 Electrostatic Discharge Damage....................................................................................... 1458 Upshift Lamp......................................................................................................... 1458 General Description (Air Induction)...................................................................................... 1458 Air Induction System................................................................................................. 1458 General Description (Fuel Metering)...................................................................................... 1458 Acceleration Mode.................................................................................................... 1458 Accelerator Controls................................................................................................. 1458 Battery Voltage Correction Mode...................................................................................... 1458 CMP Signal........................................................................................................... 1458 Clear Flood Mode..................................................................................................... 1459 Deceleration Mode.................................................................................................... 1459 Engine Speed/Vehicle Speed/Fuel Disable Mode......................................................................... 1459 Fuel Cutoff Mode..................................................................................................... 1459 Fuel Injector........................................................................................................ 1459 Fuel Metering System Components...................................................................................... 1459 Fuel Metering System Purpose......................................................................................... 1459 Fuel Pressure Regulator.............................................................................................. 1460 Fuel Pump Electrical Circuit......................................................................................... 1460 Fuel Rail............................................................................................................ 1460 Idle Air Control (IAC) Valve......................................................................................... 1460 Run Mode............................................................................................................. 1461 Starting Mode........................................................................................................ 1461 Throttle Body Unit................................................................................................... 1461 General Description (Electronic Ignition System)......................................................................... 1461 Camshaft Position (CMP) Sensor....................................................................................... 1461 Crankshaft Position (CKP) Sensor..................................................................................... 1462 Electronic Ignition.................................................................................................. 1462 Ignition Coils....................................................................................................... 1462 Ignition Control..................................................................................................... 1462 Ignition Control PCM Output.......................................................................................... 1464 Knock Sensor (KS) PCM Input.......................................................................................... 1464 Powertrain Control Module (PCM)...................................................................................... 1464 Spark Plug........................................................................................................... 1464 A/C Clutch Diagnosis..................................................................................................... 1466 A/C Clutch Circuit Operation......................................................................................... 1466 A/C Clutch Circuit Purpose........................................................................................... 1466 A/C Request Signal................................................................................................... 1466 General Description (Exhaust Gas Recirculation (EGR) System)............................................................. 1466 EGR Purpose.......................................................................................................... 1466 Linear EGR Valve..................................................................................................... 1466 Linear EGR Control................................................................................................... 1466 Linear EGR Valve Operation and Results of Incorrect Operation........................................................ 1466 EGR Pintle Position Sensor........................................................................................... 1467 General Description (Positive Crankcase Ventilation (PCV) System)........................................................ 1467 Crankcase Ventilation System Purpose................................................................................. 1467 Crankcase Ventilation System Operation............................................................................... 1467 6F ENGINE EXHAUST............................................................................................................ 1472 Service Precaution....................................................................................................... 1472 General Description...................................................................................................... 1473 Front Exhaust Pipe....................................................................................................... 1475 Front Exhaust Pipe and Associated Parts.............................................................................. 1475 Removal.............................................................................................................. 1475 Installation......................................................................................................... 1475 Three Way Catalytic Converter............................................................................................ 1476 Removal.............................................................................................................. 1476 Installation......................................................................................................... 1476 Exhaust Silencer......................................................................................................... 1477 Exhaust Silencer and Associated Parts................................................................................ 1477 Removal.............................................................................................................. 1477 Installation......................................................................................................... 1477 Rear Exhaust pipe........................................................................................................ 1478 Rear Exhaust pipe and Associated Parts............................................................................... 1478 Removal.............................................................................................................. 1478 Installation......................................................................................................... 1478 Main Data and Specifications............................................................................................. 1479 6G ENGINE LUBRICATION........................................................................................................ 1480 Service Precaution....................................................................................................... 1480 General Description...................................................................................................... 1481 Oil Pump................................................................................................................. 1482 Oil Pump and Associated Parts........................................................................................ 1482 Oil Pump and Associated Parts........................................................................................ 1482 Inspection and Repair................................................................................................ 1483 Reassembly........................................................................................................... 1484 Oil Pan and Crankcase.................................................................................................... 1486 Removal.............................................................................................................. 1486 Installation......................................................................................................... 1486 Oil Pump................................................................................................................. 1489 Removal.............................................................................................................. 1489 Installation......................................................................................................... 1489 Oil Pump Oil Seal........................................................................................................ 1491 Removal.............................................................................................................. 1491 Installation......................................................................................................... 1491 Oil Filter............................................................................................................... 1492 Removal.............................................................................................................. 1492 Installation......................................................................................................... 1492 Main Data and Specification.............................................................................................. 1493 Special Tool............................................................................................................. 1494 6H ENGINE SPEED CONTROL SYSTEM............................................................................................... 1495 Service Precaution....................................................................................................... 1495 Accelerator Pedal Control Cable.......................................................................................... 1496 Removal.............................................................................................................. 1496 Inspection........................................................................................................... 1496 Installation......................................................................................................... 1496 Adjustment........................................................................................................... 1496 Accelerator Pedal........................................................................................................ 1497 Accelerator Pedal and Associated Parts............................................................................... 1497 Removal.............................................................................................................. 1497 Installation......................................................................................................... 1497 Adjustment........................................................................................................... 1497 6J INDUCTION................................................................................................................. 1499 Service Precaution....................................................................................................... 1499 Air Cleaner Element...................................................................................................... 1500 Removal.............................................................................................................. 1500 Inspection........................................................................................................... 1500 Installation......................................................................................................... 1500 Sec.6 ENGINE(4JG2)............................................................................................................... 1501 00 SERVICE INFORMATION....................................................................................................... 1501 TROUBLESHOOTING.......................................................................................................... 1502 MAIN DATA AND SPECIFICATIONS............................................................................................. 1520 SERVICE STANDARD......................................................................................................... 1523 SERVICING................................................................................................................ 1527 FIXING TORQUE............................................................................................................ 1538 SPECIAL TOOLS............................................................................................................ 1547 6A ENGINE MECHANICAL......................................................................................................... 1551 CYLINDER HEAD............................................................................................................ 1552 VALVE SPRING, VALVE STEM OIL SEAL, VALVE, VALVE GUIDE, PUSH ROD.......................................................... 1557 CAMSHAFT, TAPPET......................................................................................................... 1564 ROCKER ARM ASSEMBLY...................................................................................................... 1569 OIL PUMP................................................................................................................. 1571 CRANKSHAFT............................................................................................................... 1575 PISTON AND CONNECTING ROD................................................................................................ 1584 CYLINDER BLOCK........................................................................................................... 1592 6A2 4JG2-NA/4JG2-TURBO ENGINE................................................................................................ 1603 GENERAL DESCRIPTION...................................................................................................... 1603 ENGINE MOUNT (RH)........................................................................................................ 1605 ENGINE MOUNT (LH)........................................................................................................ 1606 INTERCOOLER (4JG2-T only)................................................................................................ 1607 CYLINDER HEAD COVER...................................................................................................... 1608 INLET MANIFOLD........................................................................................................... 1610 EXHAUST MANIFOLD......................................................................................................... 1612 TURBOCHARGER (4JG2-T only)............................................................................................... 1613 TIMING GEAR.............................................................................................................. 1617 VALVE STEM OIL SEAL & VALVE SPRING....................................................................................... 1623 ROCKER ARM SHAFT ASSEMBLY................................................................................................ 1626 CYLINDER HEAD............................................................................................................ 1628 CRANKCASE................................................................................................................ 1633 OIL COOLER............................................................................................................... 1636 OIL PUMP ASSEMBLY........................................................................................................ 1638 PISTON, PISTON RING AND CONNECTING ROD................................................................................... 1639 CRANKSHAFT AND MAIN BEARING.............................................................................................. 1641 FRONT OIL SEAL........................................................................................................... 1647 REAR OIL SEAL............................................................................................................ 1648 ENGINE ASSEMBLY.......................................................................................................... 1650 6B ENGINE COOLING............................................................................................................ 1655 GENERAL DESCRIPTION...................................................................................................... 1655 ON-VEHICLE SERVICE....................................................................................................... 1659 WATER PUMP........................................................................................................... 1659 THERMOSTAT........................................................................................................... 1661 RADIATOR............................................................................................................. 1663 6C FUEL SYSTEM............................................................................................................... 1667 GENERAL DESCRIPTION...................................................................................................... 1667 ON-VEHICLE SERVICE....................................................................................................... 1673 FUEL FILTER ASSEMBLY................................................................................................. 1673 FUEL FILTER CARTRIGE................................................................................................. 1674 INJECTION NOZZLE..................................................................................................... 1675 INJECTION PUMP ASSEMBLY.............................................................................................. 1680 FUEL TANK............................................................................................................ 1684 FUEL GAUGE UNIT...................................................................................................... 1685 FUEL FILLER CAP...................................................................................................... 1686 ACCELERATOR CONTROL...................................................................................................... 1687 ACCELERATOR CONTROL CABLE............................................................................................ 1687 ACCELERATOR PEDAL.................................................................................................... 1689 AIR CLEANER.......................................................................................................... 1690 6D ENGINE ELECTRICAL......................................................................................................... 1691 6D1 BATTERY.............................................................................................................. 1691 GENERAL DESCRIPTION.................................................................................................. 1691 DIAGNOSIS............................................................................................................ 1691 ON-VEHICLE SERVICE................................................................................................... 1693 BATTERY CHARGING................................................................................................. 1693 JUMP STARTING.................................................................................................... 1693 REMOVAL AND INSTALLATION OF THE BATTERY.......................................................................... 1694 6D2 STARTING SYSTEM...................................................................................................... 1695 GENERAL DESCRIPTION.................................................................................................. 1695 ON-VEHICLE SERVICE................................................................................................... 1697 UNIT REPAIR.......................................................................................................... 1699 6D3 CHARGING SYSTEM...................................................................................................... 1707 GENERAL DESCRIPTION.................................................................................................. 1707 DIAGNOSIS............................................................................................................ 1710 UNIT REPAIR.......................................................................................................... 1711 6D6 QOSIII PREHEATING SYSTEM............................................................................................. 1719 GENERAL DESCRIPTION.................................................................................................. 1719 SYSTEM DIAGRAM....................................................................................................... 1720 6F ENGINE EXHAUST............................................................................................................ 1725 GENERAL DESCRIPTION...................................................................................................... 1726 HANGERS.............................................................................................................. 1726 GASKET............................................................................................................... 1726 ON-VEHICLE SERVICE....................................................................................................... 1727 FRONT EXHAUST PIPE................................................................................................... 1727 CENTER EXHAUST PIPE.................................................................................................. 1729 EXHAUST SILENCER..................................................................................................... 1731 REAR EXHAUST PIPE.................................................................................................... 1733
Sec.6 ENGINE(4JX1)............................................................................................................... 1734 6A ENGINE MECHANICAL......................................................................................................... 1734 GENERAL DESCRIPTION...................................................................................................... 0 SERVICE INFORMATION...................................................................................................... 0 SERVICE STANDARD......................................................................................................... 0 SERVICING................................................................................................................ 0 TIGHTENING TORQUE........................................................................................................ 0 SPECIAL TOOLS............................................................................................................ 0 ENGINE ASSEMBLY.......................................................................................................... 0 ENGINE MOUNT (RH)........................................................................................................ 0 ENGINE MOUNT (LH)........................................................................................................ 0 INTERCOOLER.............................................................................................................. 0 CYLINDER HEAD COVER...................................................................................................... 0 INTAKE MANIFOLD.......................................................................................................... 0 EXHAUST MANIFOLD......................................................................................................... 0 TURBOCHARGER............................................................................................................. 0 CYLINDER HEAD............................................................................................................ 0 CYLINDER HEAD GASKET..................................................................................................... 0 CAMSHAFT................................................................................................................. 0 TIMING GEAR.............................................................................................................. 0 VALVE STEM SEAL, VALVE SPRING AND ADJUSTER............................................................................... 0 VALVE CLEARANCE ADJUSTMENT............................................................................................... 0 OIL RAIL AND INJECTOR.................................................................................................... 0 CRANK CASE............................................................................................................... 0 CRANKSHAFT............................................................................................................... 0 PISTON AND CONNECTING ROD................................................................................................ 0 CYLINDER BLOCK........................................................................................................... 0 OIL PUMP ASSEMBLY........................................................................................................ 0 OIL FILTER CARTRIDGE..................................................................................................... 0 OIL COOLER............................................................................................................... 0 6B ENGINE COOLING............................................................................................................ 1834 GENERAL DESCRIPTION...................................................................................................... 0 ON-VEHICLE SERVICE....................................................................................................... 0 WATER PUMP........................................................................................................... 0 THERMOSTAT........................................................................................................... 0 RADIATOR............................................................................................................. 0 DRIVE BELT ADJUSTMENT................................................................................................ 0 6C ENGINE FUEL............................................................................................................... 1846 GENERAL DESCRIPTION...................................................................................................... 0 ON-VEHICLE SERVICE....................................................................................................... 0 FUEL FILTER ASSEMBLY................................................................................................. 0 FUEL FILTER CARTRIDGE................................................................................................ 0 INJECTOR............................................................................................................. 0 FUEL PUMP PIPE....................................................................................................... 0 HIGH PRESSURE OIL PUMP............................................................................................... 0 FUEL TANK............................................................................................................ 0 FUEL GAUGE UNIT...................................................................................................... 0 FUEL FILLER CAP...................................................................................................... 0 6D ENGINE ELECTRICAL......................................................................................................... 1868 BATTERY.................................................................................................................. 0 GENERAL DESCRIPTION.................................................................................................. 0 DIAGNOSIS............................................................................................................ 0 ON-VEHICLE SERVICE................................................................................................... 0 MAIN DATA AND SPECIFICATIONS......................................................................................... 0 STARTING SYTEM........................................................................................................... 0 GENERAL DESCRIPTION.................................................................................................. 0 ON-VEHICLE SERVICE................................................................................................... 0 STARTER.............................................................................................................. 0 UNIT REPAIR.......................................................................................................... 0 CHARGING SYSTEM.......................................................................................................... 0 GENERAL DESCRIPTION.................................................................................................. 0 DIAGNOSIS............................................................................................................ 0 UNIT REPAIR.......................................................................................................... 0 MAIN DATA AND SPECIFICATIONS......................................................................................... 0 QOS4 PREHEATING SYSTEM................................................................................................... 0 GENERAL DESCRIPTION.................................................................................................. 0 SYSTEM DIAGRAM....................................................................................................... 0 INSPECTION ON QOS4 SYSTEM OPERATION.................................................................................. 0 6E ENGINE DRIVEABILITY AND EMISSIONS......................................................................................... 1894 Specification............................................................................................................ 0 Tightening Specifications................................................................................................ 0 Diagrams and Schematics.................................................................................................. 0 ECM Wiring Diagram (1 of 6).......................................................................................... 0 ECM Wiring Diagram (2 of 6).......................................................................................... 0 ECM Wiring Diagram (3 of 6).......................................................................................... 0 ECM Wiring Diagram (4 of 6).......................................................................................... 0 ECM Wiring Diagram (5 of 6).......................................................................................... 0 ECM Wiring Diagram (6 of 6).......................................................................................... 0 ECM Pinouts.............................................................................................................. 0 ECM Pinout Table, 32-Way Connector ‐ J1 RED ‐ Upper.................................................................. 0 ECM Pinout Table, 32-Way Connector ‐ J1 RED ‐ Lower.................................................................. 0 ECM Pinout Table, 32-Way Connector ‐ J2 BLUE ‐ Upper................................................................. 0 ECM Pinout Table, 32-Way Connector ‐ J2 BLUE ‐ Lower................................................................. 0 ECM Pinout Table, 5-Way Connector ‐ J3............................................................................... 0 Component Locator........................................................................................................ 0 Sensors and Miscellaneous Component Locators......................................................................... 0 Abbreviations Charts..................................................................................................... 0 Diagnosis................................................................................................................ 0 Strategy-Based Diagnostics........................................................................................... 0 DTC Stored........................................................................................................... 0 No DTC............................................................................................................... 0 No Matching Symptom.................................................................................................. 0 Intermittents........................................................................................................ 0 No Trouble Found..................................................................................................... 0 Verifying Vehicle Repair............................................................................................. 0 General Service Information.............................................................................................. 0 Serviceability Issues................................................................................................ 0 Visual/Physical Engine Compartment Inspection........................................................................ 0 Basic Knowledge of Tools Required.................................................................................... 0 Serial Data Communications............................................................................................... 0 Class II Serial Data Communications.................................................................................. 0 On-Board Diagnostic (OBD)................................................................................................ 0 On-Board Diagnostic Tests............................................................................................ 0 Comprehensive Component Monitor Diagnostic Operation................................................................. 0 Common OBD Terms..................................................................................................... 0 The Diagnostic Executive............................................................................................. 0 DTC Types............................................................................................................ 0 Verifying Vehicle Repair............................................................................................. 0 Reading Flash Diagnostic Trouble Codes............................................................................... 0 Reading Diagnostic Trouble Codes Using a TECH 2...................................................................... 0 Tech 2 Scan Tool..................................................................................................... 0 Getting Started...................................................................................................... 0 DTC Modes............................................................................................................ 0 DTC Information Mode................................................................................................. 0 Injector Test........................................................................................................ 0 EGR Valve Test....................................................................................................... 0 Rail Pressure Control Valve Test..................................................................................... 0 Injector Balance Test................................................................................................ 0 Data Programming in Case of ECM Change............................................................................... 0 Rail Pressure Sensor Programming..................................................................................... 0 Injector Group Sign Programming (Injector Change).................................................................... 0 On-Board Diagnostic (OBD) System Check................................................................................... 0 Circuit Description.................................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Engine Control Module ECM Diagnosis...................................................................................... 0 Multiple ECM Information Sensor DTCS Set................................................................................. 0 Circuit Description.................................................................................................. 0 Diagnostic Aids...................................................................................................... 0 EGR (Exhaust Gas Recirculation) Diagnosis................................................................................ 0 Tech 2 Data Definitions and Ranges....................................................................................... 0 Typical Scan Data Values................................................................................................. 0 Test Conditions...................................................................................................... 0 4JX1-TC Engine (Automatic and Manual Transmission)................................................................... 0 No Malfunction Indicator Lamp (MIL)...................................................................................... 0 Circuit Description.................................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Malfunction Indicator Lamp (MIL) “ON” Steady............................................................................. 0 Circuit description.................................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Engine Cranks But Will Not Run........................................................................................... 0 Circuit Description.................................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Exhaust Gas Recirculation (EGR) System Check............................................................................. 0 Circuit Description.................................................................................................. 0 ECM Diagnostic Trouble Codes............................................................................................. 0 ECM Diagnostic Trouble Codes......................................................................................... 0 DTC P0107 (Flash DTC 34) MAP Sensor Circuit Low Voltage.................................................................. 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0108 (Flash DTC 34) MAP Sensor Circuit High Voltage................................................................. 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0112 (Flash DTC 23) IAT Sensor Circuit Low Voltage.................................................................. 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 Intake Air Temperature Sensor........................................................................................ 0 DTC P0113 (Flash DTC 23) IAT Sensor Circuit High Voltage................................................................. 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 Manifold Air Temperature Sensor...................................................................................... 0 DTC P0117 (Flash DTC 14) ECT Sensor Low Voltage.......................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 Engine Coolant Temperature Sensor.................................................................................... 0 DTC P0118 (Flash DTC 14) ECT Sensor High Voltage......................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 Engine Coolant Temperature Sensor.................................................................................... 0 DTC P0121 (Flash DTC 33) AP Sensor Rationality........................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0122 (Flash DTC 21) AP Sensor Low Voltage........................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0123 (Flash DTC 21) AP Sensor High Voltage.......................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 DTC P0182 (Flash DTC 15) FT Sensor Low Voltage........................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 DTC P0183 (Flash DTC 15) FT Sensor High Voltage.......................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 DTC P0192 (Flash DTC 63) Rail Pressure Sensor Low Voltage................................................................ 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0193 (Flash DTC 63) Rail Pressure Sensor High Voltage............................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1193 (Flash DTC 64) RPCV Circuit Open/Short......................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1194 (Flash DTC 61) Rail Pressure System Low Voltage................................................................ 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1195 (Flash DTC 61) Rail Pressure System High Voltage............................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1196 (Flash DTC 62) Rail Pressure System High Warning............................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 DTC P0197 (Flash DTC 16) Oil Temp Sensor Low Voltage..................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 Engine Oil Temperature Sensor........................................................................................ 0 DTC P0198 (Flash DTC 16) Oil Temp Sensor High Voltage.................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 Engine Oil Temperature Sensor........................................................................................ 0 DTC P0201 (Flash DTC 51) Injector # 1 Circuit Fault...................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 Injector Test........................................................................................................ 0 DTC P0202 (Flash DTC 52) Injector # 2 Circuit Fault...................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 Injector Test........................................................................................................ 0 DTC P0203 (Flash DTC 52) Injector # 3 Circuit Fault...................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 Injector Test........................................................................................................ 0 DTC P0204 (Flash DTC 54) Injector # 4 Circuit Fault...................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 Injector Test........................................................................................................ 0 DTC P0217 (Flash DTC 22) High Coolant Temp Waring........................................................................ 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 DTC P1217 (Flash DTC 36) High Oil Temp Warning........................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0219 (Flash DTC 11) Engine Over Speed Warning....................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0336 (Flash DTC 43) CKP (Crank Position) Sensor Out of Synchro...................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0337 (Flash DTC 43) CKP (Crank Position) Sensor No Signal........................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0341 (Flash DTC 41) CMP (Cam Position) Sensor Out of Synchro........................................................ 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 DTC P0342 (Flash DTC 41) CMP (Cam Position) Sensor No Signal............................................................. 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 DTC P0380 (Flash DTC 66) Glow Relay Circuit Open/Short................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0381 (Flash DTC 67) Glow Lamp Circuit Open/Short.................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1403 (Flash DTC 32) EGR EVRV Fault.................................................................................. 0 Circuit Description.................................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Test Description..................................................................................................... 0 DTC P1404 (Flash DTC 31) EGR VSV Circuit................................................................................. 0 Circuit Description.................................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0405 (Flash DTC 26) EGR Pressure Sensor Low Voltage................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1405 (Flash DTC 37) EGR EVRV Circuit Open/Short..................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0406 (Flash DTC 26) EGR Pressure Sensor High Voltage................................................................ 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0475 (Flash DTC 71) EXH #1 VSV Circuit.............................................................................. 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1475 (Flash DTC 71) EXH #2 VSV Circuit Open/Short................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1485 (Flash DTC 74) ITP (Intake Thorottle Position) Sensor Low Voltage.............................................. 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1486 (Flash DTC 74) ITP (Intake Throttle Position) Sensor High Voltage.............................................. 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1487 (Flash DTC 73) Intake Throttle System Circuit Open/Start....................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1488 (Flash DTC 72) Intake Throttle Motor Control Circuit Signal Gap................................................ 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0502 (Flash DTC 24) VSS (Vehicle Speed Sensor) No Signal............................................................ 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Test Description..................................................................................................... 0 DTC P0510 (Flash DTC 75) Idle SW Malfunction, Open Circuit............................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1510 (Flash DTC 75) Idle SW Malfunction Short Circuit............................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0562 (Flash DTC 35) System Voltage Too Low.......................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1562 (Flash DTC 35) System Voltage Too Low at Cranking.............................................................. 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1587 (Flash DTC 25) Brake SW Malfunction............................................................................ 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1588 (Flash DTC 25) Brake SW Malfunction............................................................................ 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0601 (Flash DTC 55) ECM Checksum Error.............................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0650 (Flash DTC 77) Check Engine Lamp Circuit Open/Short............................................................ 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P0654 (Flash DTC 27) Tachometer Circuit Open/Short................................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1655 (Flash DTC 17) Thermo Relay Circuit Open/Short................................................................. 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1657 (Flash DTC 76) ECM Main Relay Circuit Open/Short............................................................... 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 DTC P1589 (Flash DTC 47) Transmission SW Circuit Open/Short.............................................................. 0 Circuit Description.................................................................................................. 0 Action Taken When the DTC Sets....................................................................................... 0 Conditions for Clearing the MIL/DTC.................................................................................. 0 Diagnostic Aids...................................................................................................... 0 Symptom Diagnosis........................................................................................................ 0 Default Matrix Table..................................................................................................... 0 On‐Vehicle Service Camshaft Position (CMP) Sensor........................................................................ 0 Removal Procedure.................................................................................................... 0 Inspection Procedure................................................................................................. 0 Installation Procedure............................................................................................... 0 Crankshaft Position (CKP) Sensor......................................................................................... 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Engine Coolant Temperature (ECT) Sensor.................................................................................. 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Intake Air Temperature (IAT) Sensor...................................................................................... 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Manifold Absolute Pressure (MAP) Sensor.................................................................................. 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Oil Temperature (OT) Sensor.............................................................................................. 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Malfunction Indicator Lamp (MIL)......................................................................................... 0 Removal and Installation Procedure................................................................................... 0 Engine Control Module (ECM).............................................................................................. 0 Service Precaution................................................................................................... 0 Electrostatic Discharge (ESD) Damage................................................................................. 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 EEPROM................................................................................................................... 0 General Description.................................................................................................. 0 Functional Check..................................................................................................... 0 Intake Throttle Position (ITP) Sensor.................................................................................... 0 Removal Procedure.................................................................................................... 0 Function Check....................................................................................................... 0 Installation Procedure............................................................................................... 0 Vehicle Speed Sensor (VSS)............................................................................................... 0 Removal Procedure.................................................................................................... 0 Inspection Procedure................................................................................................. 0 Installation Procedure............................................................................................... 0 Air Cleaner/Air Filter................................................................................................... 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Accel Position (AP) Sensor............................................................................................... 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Accelerator Pedal Replacement............................................................................................ 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Fuel Filter Cap.......................................................................................................... 0 General Description.................................................................................................. 0 Inspection Procedure................................................................................................. 0 Fuel Filter.............................................................................................................. 0 Removal and Installation Procedure................................................................................... 0 Fuel Gauge Unit.......................................................................................................... 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Fuel Injectors........................................................................................................... 0 Removal and Installation Procedure................................................................................... 0 Fuel Temperature Sensor.................................................................................................. 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Rail Pressure (RP) Sensor................................................................................................ 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Fuel Tank................................................................................................................ 0 Removal Procedure.................................................................................................... 0 Throttle Body (TB)....................................................................................................... 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Air Conditioning (A/C) Relay............................................................................................. 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Exhaust Gas Recirculation (EGR) Vacuum Switch Valve (VSV)................................................................ 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Electronic Vacuum Regurating Valve (EVRV)................................................................................ 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Wiring and Connectors.................................................................................................... 0 Wiring Harness Service............................................................................................... 0 Connectors and Terminals............................................................................................. 0 Wire Harness Repair: Twisted Shielded Cable.............................................................................. 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Twisted Leads............................................................................................................ 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Weather-Pack Connector................................................................................................... 0 Tools Required....................................................................................................... 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 Com-Pack III............................................................................................................. 0 General Information.................................................................................................. 0 Metri-Pack............................................................................................................... 0 Tools Required....................................................................................................... 0 Removal Procedure.................................................................................................... 0 Installation Procedure............................................................................................... 0 General Description (ECM and Sensors).................................................................................... 0 57X Reference ECM Input.............................................................................................. 0 A/C Request Signal................................................................................................... 0 Crankshaft Position (CKP) Sensor..................................................................................... 0 Camshaft Position (CMP) Sensor and Signal............................................................................ 0 Engine Coolant Temperature (ECT) Sensor.............................................................................. 0 Electrically Erasable Programmable Read Only Memory (EEPROM)......................................................... 0 Intake Air Temperature (IAT) Sensor.................................................................................. 0 Manifold Absolute Pressure (MAP) Sensor.............................................................................. 0 Engine Control Module (ECM).......................................................................................... 0 ECM Function......................................................................................................... 0 ECM Components....................................................................................................... 0 ECM Voltage Description.............................................................................................. 0 ECM Input/Outputs.................................................................................................... 0 ECM Service Precautions.............................................................................................. 0 Intake Throttle Position (ITP) Sensor................................................................................ 0 Transmission Range Switch............................................................................................ 0 Accelerator Position Sensor (AP)..................................................................................... 0 Aftermarket Electrical and Vacuum Equipment.......................................................................... 0 Electrostatic Discharge Damage....................................................................................... 0 General Description (Air Induction)...................................................................................... 0 Air Induction System................................................................................................. 0 General Description (Fuel Metering)...................................................................................... 0 Deceleration Mode.................................................................................................... 0 Fuel Injector........................................................................................................ 0 Fuel Metering System Components...................................................................................... 0 A/C Clutch Diagnosis..................................................................................................... 0 A/C Request Signal................................................................................................... 0 General Description Exhaust Gas Recirculation (EGR) System............................................................... 0 EGR Purpose.......................................................................................................... 0 Fuse and Relay Panel (Underhood Electrical Center) RHD................................................................... 0 Fuse and Relay Panel (Underhood Electrical Center) LHD................................................................... 0 6F ENGINE EXHAUST............................................................................................................ 2124 GENERAL DESCRIPTION...................................................................................................... 0 HANGERS.............................................................................................................. 0 GASKET............................................................................................................... 0 ON-VEHICLE SERVICE....................................................................................................... 0 FRONT EXHAUST PIPE................................................................................................... 0 CENTER EXHAUST PIPE.................................................................................................. 0 EXHAUST SILENCER..................................................................................................... 0 REAR EXHAUST PIPE.................................................................................................... 0 6G ENGINE LUBRICATION........................................................................................................ 2132 GENERAL DESCRIPTION...................................................................................................... 0 LUBRICATION CHART.................................................................................................... 0 OIL FLOW............................................................................................................. 0 OIL PUMP SPECIFICATIONS.............................................................................................. 0 OIL FILTER SPECIFICATIONS............................................................................................ 0 SUB OIL FILTER SPECIFICATIONS........................................................................................ 0 OIL PUMP................................................................................................................. 0 OIL COOLER ASSEMBLY...................................................................................................... 0 OIL COOLER SPECIFICATIONS............................................................................................ 0 OIL FILTER............................................................................................................... 0 SUB OIL FILTER....................................................................................................... 0 6H ENGINE SPEED CONTROL...................................................................................................... 2138 GENERAL DESCRIPTION...................................................................................................... 0 ACCELERATOR PEDAL........................................................................................................ 0 6J INDUCTION................................................................................................................. 2142 GENERAL DESCRIPTION...................................................................................................... 0 AIR CLEANER.............................................................................................................. 0 TURBOCHARGER............................................................................................................. 0 INTERCOOLER.............................................................................................................. 0 INTAKE THROTTLE VALVE.................................................................................................... 0 INTAKE MANIFOLD.......................................................................................................... 0 MAIN DATA AND SPECIFICATIONS............................................................................................. 0
PLEASE NOTE:
⦁ This is the SAME MANUAL used by the dealerships to diagnose your vehicle
⦁ No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
⦁ Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
⦁ So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
