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SUZUKI SQ420VD SQ420WD WITH RHW ENGINE GRAND VITARA SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
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“Suzuki SQ420VD SQ420WD with RHW Engine Grand Vitara Supplementary Service Manual” offers additional instructions for precise maintenance, complementing the main manual for comprehensive care and optimal performance of the specific model.
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SUZUKI SQ420VD SQ420WD WITH RHW ENGINE GRAND VITARA SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
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SUZUKI SQ420VD SQ420WD WITH RHW ENGINE GRAND VITARA SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Language : English
Pages : 747
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
SUZUKI SQ420VD SQ420WD WITH RHW ENGINE GRAND VITARA SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD
Bookcover........................................................................................................... 1 99501_68D10_01E..................................................................................................... 2 TOP............................................................................................................. 0 Manual List..................................................................................................... 0 Important....................................................................................................... 2 WARNING/CAUTION/NOTE........................................................................................ 2 Foreword........................................................................................................ 3 Table of Contents............................................................................................... 5 SECTION 0A...................................................................................................... 7 Precautions................................................................................................. 8 General Precautions..................................................................................... 8 Identification Information.................................................................................. 11 Vehicle Identification Number........................................................................... 11 Engine Identification Number............................................................................ 11 Transmission Identification Number...................................................................... 11 Warning, Caution and Information Labels..................................................................... 12 Metric Information.......................................................................................... 13 Metric Fasteners........................................................................................ 13 SECTION 0B...................................................................................................... 15 Maintenance Schedule........................................................................................ 16 Maintenance Schedule Under Normal Driving Conditions.................................................... 16 Maintenance Recommended Under Severe Driving Conditions................................................. 17 Maintenance Service......................................................................................... 19 Engine.................................................................................................. 19 Accessary drive belt................................................................................ 19 Camshaft timing belt................................................................................ 20 Engine oil and oil filter........................................................................... 20 Engine coolant...................................................................................... 22 Exhaust system...................................................................................... 23 Heater (Glow) plugs................................................................................. 23 Fuel System............................................................................................. 24 Air cleaner filter.................................................................................. 24 Fuel lines and connections.......................................................................... 24 Fuel filter......................................................................................... 24 Fuel tank........................................................................................... 25 Chassis and Body........................................................................................ 25 Manual transmission oil............................................................................. 25 Automatic transmission fluid........................................................................ 25 Power steering (P/S) system (if equipped)........................................................... 26 Recommended Fluids and Lubricants........................................................................... 27 SECTION 1A...................................................................................................... 29 General Description......................................................................................... 30 Major Components........................................................................................ 31 Wiring Circuit.......................................................................................... 32 General Diagnosis........................................................................................... 32 Diagnosis Table......................................................................................... 32 HVAC Diagnosis.............................................................................................. 33 On-Board Diagnostic System.............................................................................. 33 On-Vehicle Service.......................................................................................... 34 Blower Unit............................................................................................. 34 Blower Motor............................................................................................ 35 Supplementary Heater.................................................................................... 37 Supplementary heater No.1........................................................................... 37 Supplementary heater No.2........................................................................... 37 Supplementary Heater Relay.............................................................................. 38 Heater Unit............................................................................................. 39 SECTION 1B...................................................................................................... 43 Major Components and Location............................................................................... 45 Wiring Circuit.............................................................................................. 46 General Diagnosis........................................................................................... 48 General Diagnosis Table................................................................................. 48 Inspection of HVAC Control Module and Its Circuits...................................................... 53 HVAC control module voltage table................................................................... 54 Reference waveform No.1............................................................................. 57 Reference waveform No.2............................................................................. 58 Reference graph No.1................................................................................ 59 Inspection of A/C Controller and Its Circuits........................................................... 60 A/C controller voltage value table.................................................................. 61 Scan Tool Data.......................................................................................... 62 Scan tool data definitions.......................................................................... 63 On-Vehicle Service.......................................................................................... 66 Heater and Cooling Unit................................................................................. 66 A/C Controller.......................................................................................... 69 A/C Signal Relay........................................................................................ 69 A/C Compressor Relay and A/C Condenser Cooling Fan Relays............................................... 70 Compressor Assembly..................................................................................... 70 Compressor Drive Belt................................................................................... 73 Required Service Materials.................................................................................. 73 Special Tool............................................................................................ 74 SECTION 3B1..................................................................................................... 75 General Description......................................................................................... 77 Power Steering (P/S) Pump............................................................................... 77 Diagnosis................................................................................................... 78 Power Steering Fluid.................................................................................... 78 Power steering fluid level check.................................................................... 78 Power Steering Pump Drive Belt.......................................................................... 78 Hydraulic Pressure in P/S Circuit....................................................................... 78 Hydraulic pressure check............................................................................ 78 On-Vehicle Service.......................................................................................... 80 Power Steering Gear Box Assembly........................................................................ 80 Power Steering Pump..................................................................................... 82 Tightening Torque Specifications............................................................................ 89 Required Service Material................................................................................... 89 Special Tool................................................................................................ 90 SECTION 3E...................................................................................................... 91 On-vehicle Service.......................................................................................... 92 Rear Axle Shaft and Wheel Bearing....................................................................... 92 Rear Axle Housing....................................................................................... 92 Tightening Torque Specification............................................................................. 93 Required Service Material................................................................................... 93 SECTION 5....................................................................................................... 95 Check and Adjustment........................................................................................ 96 Fluid Pressure Test (if equipped with LSPV)............................................................. 96 Tightening Torque Specification............................................................................. 98 Required Service Material................................................................................... 98 Special Tool................................................................................................ 99 SECTION 6-1.....................................................................................................101 OTHER THAN EOBD SPEC........................................................................................105 General Information.........................................................................................105 Identification of Emission Control System...............................................................105 Statement of Cleanliness and Care.......................................................................105 General Information on Engine Service...................................................................106 Precaution on fuel system service...................................................................107 Fuel pressure relief procedure......................................................................108 Fuel leakage check procedure........................................................................108 Engine Diagnosis............................................................................................109 General Description.....................................................................................109 On-Board Diagnostic System..............................................................................109 Precaution in Diagnosing Trouble........................................................................112 Engine Diagnostic Flow Table............................................................................113 Diagnostic step details.............................................................................114 Malfunction Indicator Lamp (MIL) Check..................................................................117 Diagnostic Trouble Code (DTC) Check.....................................................................117 Diagnostic Trouble Code (DTC) Clearance.................................................................117 Fail-Safe Table.........................................................................................118 Diagnostic Trouble Code (DTC) Table.....................................................................119 Visual Inspection.......................................................................................123 Engine Basic Check......................................................................................124 Engine Diagnosis Table..................................................................................125 Inspection of ECM and Its Circuits......................................................................131 Voltage check.......................................................................................131 Resistance check....................................................................................133 Table A-1 Malfunction Indicator Lamp Circuit Check – MIL Does Not Come “ON” or Dims at Ignition S.......134 Table A-2 Malfunction Indicator Lamp Circuit Check – MIL Remains “ON” after Engine Starts...............135 Table A-3 ECM Power and Ground Circuit Check – MIL Doesn’t Light at Ignition Switch ON and Engine.......136 DTC P0100 (DTC P0100) Mass Air Flow Circuit Malfunction.................................................137 DTC P0101 (P0100) MAF Sensor Circuit Range/Performance Problem..........................................140 DTC P0110 Intake Air Temp. (IAT) Circuit Malfunction....................................................141 DTC P0115 (DTC P0115) Engine Coolant Temp. Sensor Circuit Malfunction...................................143 DTC P0121 (DTC P0120) Throttle Position Circuit Range/Performance Problem...............................145 DTC P0604 (P0120) Throttle Position Sensor Monitoring System Malfunction................................145 DTC P0180 Fuel Temperature Sensor Circuit Malfunction...................................................147 DTC P0190 (P0190) Fuel Rail Pressure Sensor Circuit Malfunction.........................................149 DTC P0191 (P0230) Fuel Rail Pressure Sensor/Pressure Regulator Consistency Function.....................151 DTC P1112 (P0230) Fuel Pressure Monitoring Circuit Malfunction..........................................151 DTC P0201 (P0200) Injector Circuit Malfunction Cylinder 1...............................................153 DTC P0202 (P0200) Injector Circuit Malfunction Cylinder 2...............................................153 DTC P0203 (P0200) Injector Circuit Malfunction Cylinder 3...............................................153 DTC P0204 (P0200) Injector Circuit Malfunction Cylinder 4...............................................153 DTC P0215 Double Relay Circuit Malfunction..............................................................155 DTC P0230 Fuel Pump Supply Circuit Malfunction..........................................................157 DTC P0243 (P0243) Turbo Pressure Solenoid Valve Circuit Range/Performance Problem.......................159 DTC P0245 (P0243)/P0246 (P0243) Turbo Pressure Solenoid Valve Circuit Range/Performance Problem.........161 DTC P0380 (P0380)/P1404 (P0380) Pre/Post Heat Relay Circuit Malfunction.................................162 DTC P0381 Glow Indicator Lamp Circuit Malfunction.......................................................164 DTC P0401 (P0903) EGR Solenoid Valve Flow Insufficient Detected.........................................166 DTC P0402 (P0903) EGR Solenoid Valve Flow Excessive Detected............................................166 DTC P0403 (P0403) EGR Solenoid Valve Circuit Malfunction................................................167 DTC P0561 (P0560) Stabilization of Sensor Supply........................................................169 DTC P0603/P0606/P1171 ECM Function......................................................................169 DTC P1169 (P0170) Condenser Voltage Function 1..........................................................169 DTC P1170 (P0170) Condenser Voltage Function 2..........................................................169 DTC P1101 (P0105) Barometric Pressure Sensor Circuit Malfunction........................................169 DCT P1107 Swirl Control Solenoid Valve Circuit Malfunction..............................................170 DTC P1108 Radiator Fan High Speed Circuit Malfunction...................................................172 DTC P1109 Radiator Fan Low Speed Circuit Malfunction....................................................174 DTC P1110 A/C Signal Circuit Malfunction................................................................175 DTC P1135 3rd Piston Deactivator (Injection Pump Solenoid Valve) Circuit Malfunction....................176 DTC P1138 (P0230) Fuel Pressure Regulator Circuit Malfunction...........................................178 DTC P1402 (P0510) Throttle Solenoid Valve Circuit Malfunction...........................................180 DTC P1511 Ignition Switch Circuit Malfunction...........................................................182 DTC P1519 Radiator Fan Circuit Malfunction..............................................................183 DTC P1606 MIL Circuit Malfunction.......................................................................184 DTC P1608 ECT Warning Lamp Circuit Malfunction..........................................................186 DTC P1614 (P0560) Sensor Supply Function................................................................188 DTC P0221 (P0220) Throttle Position Range/Performance Problem 2.........................................191 DTC P0335 (P0335) Crankshaft Position Sensor Circuit Malfunction........................................193 DTC P0340 (P0335/P0340) Camshaft Position Sensor Circuit Malfunction....................................195 DTC P0500 (P0500) Vehicle Speed Sensor Circuit Malfunction..............................................198 DTC P0235 (P0235) Intake Air Pressure Sensor Circuit Malfunction........................................200 DTC P0560 (P0560) Power Supply Circuit Malfunction......................................................202 DTC P1613 ECM Not Registered............................................................................203 DTC P1517 Immobilizer System Malfunction................................................................204 TABLE B-1 Fuel Pump Circuit Inspection..................................................................206 TABLE B-2 Fuel Pressure Inspection......................................................................207 EOBD SPEC...................................................................................................208 General Information.........................................................................................208 Identification of Emission Control System...............................................................208 Statement of Cleanliness and Care.......................................................................208 General Information on Engine Service...................................................................209 Precaution on fuel system service...................................................................210 Fuel pressure relief procedure......................................................................211 Fuel leakage check procedure........................................................................211 Engine Diagnosis............................................................................................212 General Description.....................................................................................212 On-Board Diagnostic System..............................................................................212 Precaution in Diagnosing Trouble........................................................................215 Engine Diagnostic Flow Table............................................................................216 Diagnostic step details.............................................................................217 Malfunction Indicator Lamp (MIL) Check..................................................................220 Diagnostic Trouble Code (DTC) Check.....................................................................220 Diagnostic Trouble Code (DTC) Clearance.................................................................220 Fail-Safe Table.........................................................................................221 Diagnostic Trouble Code (DTC) Table.....................................................................224 Visual Inspection.......................................................................................229 Engine Basic Check......................................................................................230 Engine Diagnosis Table..................................................................................231 Inspection of ECM and Its Circuits......................................................................237 Voltage check.......................................................................................237 Resistance check....................................................................................239 Table A-1 Malfunction Indicator Lamp Circuit Check – MIL Does Not Come “ON” or Dims at Ignition S.......240 Table A-2 Malfunction Indicator Lamp Circuit Check – MIL Remains “ON” after Engine Starts...............241 Table A-3 ECM Power and Ground Circuit Check – MIL Doesn’t Light at Ignition Switch ON and Engine.......242 DTC P0100 (P0102/P0103/P3007/P3008) Mass Air Flow Circuit (Low Input/High Input/Plausibility at L.......243 DTC P0110 (P0112/P0113) Intake Air Temperature Sensor Circuit (Low/High)................................246 DTC P0115 (P0115/P0117/P0118) Engine Coolant Temperature Circuit (Malfunction/Low/High).................248 DTC P0220 (P0222/P0223/P0224) Pedal Position Sensor “No.1” Circuit (Low/ High/Intermittent).............250 DTC P2299 Accelerator Pedal Position Incompatible.......................................................250 DTC P0180 (P0182/P0183) Fuel Temperature Sensor Circuit (Low/High)......................................252 DTC P0190 (P0192/P0193/P0194) Fuel Rail Pressure Sensor Circuit (Low/High/ Intermittent)................254 DTC P0089 (P0089/P0087, P1113/P0088, P1116/P0094) Fuel Pressure Regulator Performance (Malfunctio.......256 DTC P0201 (P0201/P0261/P0262/P1372) Injector Circuit – Cylinder 1 (Malfunction/Low/High/ Short).........258 DTC P0202 (P0202/P0264/P0265/P1373) Injector Circuit – Cylinder 2 (Malfunction/Low/High/ Short).........260 DTC P0203 (P0203/P0267/P0268/P1374) Injector Circuit – Cylinder 3 (Malfunction/Low/High/ Short).........262 DTC P0204 (P0204/P0267/P0268/P1374) Injector Circuit – Cylinder 4 (Malfunction/Low/High/ Short).........264 DTC P1169 Condenser 1 Voltage Too Low/High..............................................................266 DTC P1170 Condenser 2 Voltage Too Low/High..............................................................266 DTC P0215 Engine Shutoff Solenoid.......................................................................269 DTC P0230 Fuel Pump Primary Circuit.....................................................................271 DTC P0243 (P0243/P0246) Turbo Charger Waste Gate Solenoid (Malfunction/ High)...........................273 DTC P0245 (P0245) Turbo Charger Waste Gate Solenoid Low.................................................273 DTC P0234 (P0243) Turbo Charger Over Boost Condition....................................................275 DTC P0299 (P0299) Turbo Charger Under Boost.............................................................275 DTC P0380 (P1351/P1352/P1349/P1350) Glow Plug Circuit (Excess Voltage/ Relay Jammed/Short/Open).........276 DTC P1404 TL4226 Circuit Malfunction....................................................................276 DTC P0381 Glow Plug Indicator Circuit...................................................................278 DTC P0401 (P0401) Exhaust Gas Recirculation Flow Insufficient Detected..................................280 DTC P0400 (P0400/P0402/P2143/P2145) Exhaust Gas Recirculation Flow (Malfunction/Excessive Detecte.......281 DTC P2144 (P2144) Exhaust Gas Recirculation Vent Control Circuit Low....................................281 DTC P0105 (P0107/P0108) Barometric Pressure Sensor Circuit (Low Input/ High Input)......................283 DTC P0561 (P0642/P0643) Sensor Reference Voltage Circuit (Low/High).....................................283 DTC P0603 (P0603) Internal Control Module Keep Alive Memory (KAM) Error.................................283 DTC P0604 (P0604) Internal Control Module Random Access Memory (RAM) Error..............................283 DTC P1107 (P2009/P2010) Intake Manifold Runner Control Circuit (Low/High)...............................284 DTC P0480 Fan 1 Control Circuit.........................................................................286 DTC P0481 Fan 2 Control Circuit.........................................................................288 DTC P3004 (P3005/P3006) 3rd Piston Deactivator Circuit (Short/Open).....................................289 DTC P0090 (P0090/P0091/P0092) Fuel Pressure Regulator Control Circuit (Malfunction/Low/High)............291 DTC P0606 (P0606) ECM Processor.........................................................................291 DTC P1171 ECU Function (ECU Internal Fault).............................................................291 DTC P0120 (P0487/P2142) Exhaust Gas Recirculation Throttle Position Control Circuit (Malfunction/.......293 DTC P2141 (P2141) Exhaust Gas Recirculation Throttle Position Control Circuit Low.......................293 DTC P1511 Ignition Switch Circuit Malfunction...........................................................295 DTC P0485 Fan Power/Ground Circuit......................................................................296 DTC P0650 (P0650/P1642) Malfunction Indicator Lamp (MIL) Control Circuit Malfunction (Malfunction.......297 DTC P0608 (P0658/P0659) Actuator Supply Voltage Circuit 1 (Low/High)....................................299 DTC P0609 (P2670/P2671) Actuator Supply Voltage Circuit 2 (Low/High)....................................301 DTC P0225 (P0224/P0227/P0228/P2137) Pedal Position Sensor “No.2” Circuit (Intermittent/Low/High/V.......304 DTC P0335 (P0335) Crankshaft Position Sensor Circuit....................................................306 DTC P0340 (P0341/P0343/P0344/P0016) Camshaft Position Sensor Circuit (Performance/High/Intermitte.......308 DTC P0500 (P0500/P0501) Vehicle Speed Sensor (Malfunction/Performance)..................................311 DTC P0235 (P0069/P0235, P1281/P0237/P0238) Turbo Charger Boost Sensor Circuit (Manifold Absolute .......313 DTC P0560 (P0562/P0563) System Voltage (Low/High).......................................................315 DTC P1613 ECM Not Registered............................................................................316 DTC P1517 Immobilizer System Malfunction................................................................317 TABLE B-1 Fuel Pump Circuit Inspection..................................................................319 TABLE B-2 Fuel Pressure Inspection......................................................................320 Special Tool................................................................................................321 SECTION 6A3.....................................................................................................323 CONTENTS....................................................................................................323 Service Precaution..........................................................................................324 On-Vehicle Service..........................................................................................324 Compression Check.......................................................................................324 Oil Pressure Check......................................................................................325 Air Cleaner Element.....................................................................................326 Intercooler.............................................................................................327 Cylinder Head Cover.....................................................................................328 Turbocharger............................................................................................332 Intake Manifold.........................................................................................334 Exhaust Manifold........................................................................................334 Timing Belt and Belt Tensioner..........................................................................337 Oil Pressure Switch.....................................................................................345 Oil Cooler..............................................................................................345 Oil Pan and Oil Pump Strainer...........................................................................346 Oil Pump................................................................................................351 Camshafts and Valve Rockers.............................................................................355 Valves and Cylinder Head................................................................................362 Swirl Control Solenoid Valve............................................................................369 Piston, Piston Rings, Connecting Rods and Cylinders.....................................................371 Unit Repair Overhaul........................................................................................376 Engine Assembly.........................................................................................376 Main Bearings, Crankshaft and Cylinder Block............................................................379 Special Tools...............................................................................................389 Required Service Materials..................................................................................390 Tightening Torque Specifications............................................................................391 SECTION 6B......................................................................................................393 General Description.........................................................................................394 Cooling System Component................................................................................394 Cooling System Circulation..............................................................................395 Coolant Degassing Tank..................................................................................396 Water Pump..............................................................................................396 Thermostat..............................................................................................396 Cooling Fan.............................................................................................397 Coolant.................................................................................................397 Anti-freeze proportioning chart:....................................................................397 Coolant capacity....................................................................................397 Diagnosis...................................................................................................398 Diagnosis Table.........................................................................................398 Maintenance.................................................................................................399 Coolant Level Check.....................................................................................399 Cooling System Service..................................................................................399 Cooling System Flush....................................................................................400 On-Vehicle Service......................................................................................402 Cooling System Draining.................................................................................402 Cooling System Refill...................................................................................402 Cooling Water Pipes or Hoses............................................................................402 Thermostat..............................................................................................403 Radiator................................................................................................405 Radiator Fan Relay......................................................................................406 Water Pump..............................................................................................406 Required Service Materials..................................................................................408 Tightening Torque Specifications............................................................................408 Special Tool................................................................................................408 SECTION 6C......................................................................................................409 General Description.........................................................................................410 Fuel System.............................................................................................410 On-Vehicle Service..........................................................................................410 Water Draining of Fuel Filter...........................................................................410 Air Bleeding of Fuel System.............................................................................410 Fuel Filter Assembly....................................................................................410 Fuel filter assembly components.....................................................................410 Fuel filter element.................................................................................411 Fuel filter assembly................................................................................412 Fuel Tank Assembly......................................................................................414 Fuel tank assembly components.......................................................................414 2-way check valve (tank pressure control valve).....................................................414 Fuel tank...........................................................................................415 Fuel Pump and Fuel Level Gauge..........................................................................416 Fuel pump...........................................................................................417 Fuel level gauge....................................................................................418 Injection Pump..........................................................................................418 Tightening Torque Specifications............................................................................419 Special Tools...............................................................................................419 SECTION 6E3.....................................................................................................421 General Description.........................................................................................423 Identification of Emission Control System...............................................................423 System Diagram..........................................................................................424 Electronic Control System...............................................................................425 System location diagram.............................................................................425 System wiring diagram...............................................................................426 Air Intake System.......................................................................................430 Fuel Delivery System....................................................................................431 On-Vehicle Service..........................................................................................432 Accelerator Cable Adjustment............................................................................432 Idle Speed Inspection...................................................................................432 Air Intake System.......................................................................................433 Vacuum hose routing diagram.........................................................................433 Throttle valve assembly.............................................................................434 EGR throttle solenoid valve.........................................................................435 Vacuum pump.........................................................................................435 Boost pressure regulator solenoid valve.............................................................438 Glow plug...........................................................................................439 Fuel Delivery System....................................................................................441 Precautions.........................................................................................441 Low pressure fuel supply system.....................................................................443 Fuel Leakage Check......................................................................................444 Fuel pump...........................................................................................444 Fuel heater.........................................................................................444 Fuel injector.......................................................................................445 Common rail (High pressure fuel injection rail).....................................................448 Injection pump......................................................................................451 Electronic Control System...............................................................................454 Engine control module (ECM).........................................................................454 ECM registration....................................................................................455 Registration data check.............................................................................456 Mass air flow sensor (MAF sensor)...................................................................456 Throttle position sensor (TP sensor) (accelerator pedal position sensor)............................458 Fuel temperature sensor assembly....................................................................459 Fuel (rail) pressure sensor.........................................................................460 Engine coolant temperature sensor (ECT sensor)......................................................461 VSS.................................................................................................462 Camshaft position sensor (CMP sensor)...............................................................463 Crankshaft position sensor (engine speed sensor)....................................................463 Intake air pressure sensor (manifold absolute pressure sensor)......................................465 Radiator fan control system.........................................................................466 Radiator fan........................................................................................466 Radiator fan relay 1 (high/low).....................................................................467 Radiator fan relay 2 (high).........................................................................468 Radiator fan relay 3 (low)..........................................................................468 Double relay........................................................................................469 Pre/post heating relay (control unit)...............................................................470 EGR System..............................................................................................471 EGR valve component.................................................................................471 EGR valve and EGR cooler............................................................................472 Vacuum hose.........................................................................................473 EGR solenoid valve..................................................................................473 Swirl Control Solenoid Valve............................................................................474 Tightening Torque Specifications............................................................................476 Special Tools...............................................................................................477 SECTION 6G......................................................................................................479 General Description.........................................................................................480 Cranking Circuit........................................................................................480 Starting Motor Circuit..................................................................................480 Starting Motor..........................................................................................481 Diagnosis...................................................................................................482 Unit Repair Overhaul........................................................................................483 Generator...............................................................................................483 Dismounting.........................................................................................483 Remounting..........................................................................................483 Disassembly and reassembly..........................................................................484 Inspection..........................................................................................485 Performance test....................................................................................488 Specifications..............................................................................................489 2.0 kW reduction type...................................................................................489 Required Service Materials..................................................................................489 Tightening Torque Specifications............................................................................490 SECTION 6H......................................................................................................491 On-Vehicle Service..........................................................................................492 Generator...............................................................................................492 Generator belt......................................................................................492 Unit Repair Overhaul........................................................................................494 Generator...............................................................................................494 Specifications..............................................................................................497 Generator...............................................................................................497 Tightening Torque Specifications............................................................................497 Special Tools...............................................................................................497 SECTION 6K......................................................................................................499 General Description.........................................................................................500 Exhaust System Components...............................................................................500 Maintenance.................................................................................................501 On-Vehicle Service..........................................................................................502 Exhaust Manifold........................................................................................502 Muffler.................................................................................................502 SECTION 7A2.....................................................................................................503 General Description.........................................................................................504 System Description......................................................................................504 Diagnosis...................................................................................................504 On-Vehicle Service..........................................................................................505 Transmission Gear Oil...................................................................................505 Transmission Shift Control Lever........................................................................506 Back Up Light Switch....................................................................................506 Engine Rear Mounting....................................................................................506 Dismounting of Transmission Unit........................................................................506 Remounting of Transmission Unit.........................................................................508 Unit Repair.................................................................................................510 Tightening Torque Specifications............................................................................510 SECTION 7B1.....................................................................................................511 General Description.........................................................................................513 Clutch/Brake Functions..................................................................................515 Table of Component Operation............................................................................516 Electronic Shift Control System.........................................................................517 Change mechanism....................................................................................519 Operation of shift solenoids and TCC solenoid.......................................................519 Diagnosis...................................................................................................521 On-Board Diagnostic System..............................................................................521 Precaution in Diagnosing Trouble........................................................................522 Automatic Transmission Diagnostic Flow Table............................................................523 “O/D OFF” Lamp Check....................................................................................526 Diagnostic Trouble Code (DTC) Check.....................................................................526 Diagnostic Trouble Code Clearance.......................................................................528 Diagnostic Trouble Code Table...........................................................................529 Fail Safe Table.........................................................................................531 Visual Inspection.......................................................................................532 A/T Basic Check.........................................................................................533 Trouble Diagnosis Table 1...............................................................................534 Trouble Diagnosis Table 2...............................................................................536 Trouble Diagnosis Table 3...............................................................................537 Engine Brake Test.......................................................................................541 Stall Test..............................................................................................541 Time Lag Test...........................................................................................543 Line Pressure Test......................................................................................544 “P” Range Test..........................................................................................545 Table A-1: No Gear Shift to O/D.........................................................................546 Table A-2: No Lock-Up Occurs............................................................................547 Table B-1: “O/D OFF” Lamp Circuit Check (“O/D OFF” Lamp Doesn’t Light at Ignition Switch On)............548 Table B-2: “O/D OFF” Lamp Circuit Check (“O/D OFF” Lamp Comes On Steadily)..............................549 Inspection of TCM and Its Circuits......................................................................550 Wire Harness and Connectors.............................................................................551 Scan Tool Data..........................................................................................552 Scan Tool Data Definition...............................................................................553 DTC P0705 (DTC NO.34) Transmission Range Sensor (Switch) Circuit Malfunction............................554 DTC P0710 (DTC NO.36/38) Transmission Fluid Temperature Sensor Circuit Malfunction......................557 DTC P0715 (DTC NO.37) Input/Turbine Speed Sensor Circuit Malfunction....................................559 DTC P0720 (DTC NO.31) Output Speed Sensor Circuit Malfunction...........................................562 DTC P0725 (DTC NO.35) Engine Speed Input Circuit Malfunction............................................565 DTC P0743 (DTC NO.25/26) TCC (Lock-Up) System Electrical................................................567 DTC P0748 (DTC NO.41/42) Pressure Control Solenoid Electrical...........................................569 DTC P0753 (DTC NO.21/22)/ P0758 (DTC NO.23/24) Shift Solenoid-A/ Shift Solenoid-B Electrical............571 DTC P1700 (DTC NO.32/33) Acceleration Stroke Signal Input Malfunction...................................573 DTC P1702 (DTC NO.52) Internal Malfunction of TCM.......................................................575 DTC P1730 (DTC NO.64) Engine Torque Signal Circuit Malfunction..........................................576 On-Vehicle Service..........................................................................................578 Maintenance Service.....................................................................................578 Fluid level.........................................................................................578 Fluid change........................................................................................579 Oil Cooler Hoses........................................................................................580 Manual Selector Assembly................................................................................580 Select Cable............................................................................................582 Transmission Range Sensor (Switch)......................................................................583 Input Shaft Speed Sensor................................................................................584 Output Shaft Speed Sensor...............................................................................585 A/T Fluid Temperature Sensor............................................................................587 O/D Off Switch..........................................................................................587 Solenoid Valves (Shift Solenoid Valves, TCC Solenoid Valve and Pressure Control Solenoid Valve).........588 Throttle Position Sensor................................................................................591 Transmission Control Module (TCM).......................................................................591 4WD LOW Switch..........................................................................................592 Oil Cooler Pipes........................................................................................592 Automatic Transmission Assembly (with Transfer).........................................................593 Unit Repair.................................................................................................599 Precautions.............................................................................................599 Part Inspection and Correction Table....................................................................600 Unit Disassembly........................................................................................601 Subassembly.............................................................................................618 Oil pump assembly...................................................................................618 O/D clutch assembly and O/D planetary gear assembly.................................................622 O/D brake assembly..................................................................................628 Direct clutch assembly..............................................................................632 Forward clutch assembly.............................................................................636 Sun gear and one-way No.3 clutch assembly...........................................................641 Forward brake assembly..............................................................................643 Rear planetary gear carrier assembly and output shaft...............................................646 Valve body assembly.................................................................................651 Unit Assembly...........................................................................................652 Tightening Torque Specifications............................................................................671 Required Service Material...................................................................................672 Special Tool................................................................................................672 SECTION 7C1.....................................................................................................675 CONTENTS....................................................................................................675 Unit Pepair.................................................................................................676 Clutch Cover, Clutch Disc and Flywheel..................................................................676 Tightening Torque Specifications............................................................................679 Required Service Material...................................................................................680 Special Tool................................................................................................680 SECTION 7E......................................................................................................681 General Description.........................................................................................681 4WD Control System......................................................................................682 System circuit and operation........................................................................683 Components and functions............................................................................684 Diagnosis...................................................................................................685 Diagnosis Table.........................................................................................685 Differential assembly...............................................................................685 4WD control system diagnostic flow table............................................................685 4WD Control Circuit Inspection..........................................................................688 Voltage check.......................................................................................688 On-Vehicle Service..........................................................................................689 Maintenance Service.....................................................................................689 Gear oil change.....................................................................................689 Removal and Installation................................................................................690 Differential mountings..............................................................................690 Rear mounting (for front differential carrier)......................................................692 Dismounting.............................................................................................692 Remounting..............................................................................................694 Unit Repair.................................................................................................695 Tightening Torque Specifications............................................................................695 Required Service Material...................................................................................695 Special Tool................................................................................................695 SECTION 7F......................................................................................................697 General Description.........................................................................................698 Diagnosis...................................................................................................698 On-vehicle Service..........................................................................................699 Maintenance Service.....................................................................................700 Changing oil........................................................................................700 Rear Differential Assembly..............................................................................701 Dismounting.........................................................................................701 Remounting..........................................................................................701 Unit Repair.................................................................................................702 Disassembling Unit......................................................................................702 Component Inspection....................................................................................705 Sub-Assembly Adjustment and Reassembly..................................................................705 Differential carrier................................................................................705 Differential case...................................................................................705 Differential side bearing...........................................................................707 Drive bevel pinion..................................................................................708 Assembling Unit.........................................................................................712 Tightening Torque Specification.............................................................................715 Required Service Material...................................................................................715 Special Tool................................................................................................716 SECTION 8C......................................................................................................719 General Description.........................................................................................720 Combination Meter.......................................................................................720 Combination meter internal circuits and couplers....................................................720 On-Vehicle Service..........................................................................................722 Fuel Meter/Fuel Gauge Unit..............................................................................722 Fuel level gauge....................................................................................722 Engine Coolant Temperature (ECT) Sensor.................................................................722 Oil Pressure Switch.....................................................................................722 SECTION 8G......................................................................................................723 General Description.........................................................................................724 Wiring Circuit..........................................................................................725 Ignition Key............................................................................................726 Coil Antenna............................................................................................726 Immobilizer Control Module..............................................................................726 ECM.....................................................................................................726 On-board Diagnostic System (Self-diagnosis Function)....................................................727 Diagnosis...................................................................................................728 Precautions in Diagnosing Troubles......................................................................728 Precautions in identifying diagnostic trouble code..................................................728 Note on system circuit inspection...................................................................728 Precautions after Replacing ECM or Immobilizer Control Module...........................................728 Immobilizer Control System Diagnostic Flow Table........................................................729 Diagnostic Trouble Code (DTC) Check (Immobilizer Control Module)........................................730 Diagnostic Trouble Code Table...........................................................................730 Table A – Scan Tool Can Not Communicate with Immobilizer Control Module.................................731 DTC11 Transponder Code Not Matched......................................................................732 DTC31 Transponder Code Not Registered...................................................................732 DTC12 Fault in Immobilizer Control Module...............................................................733 DTC13 No Transponder Code Transmitted from Ignition Key.................................................733 DTC14 Coil Antenna Circuit Malfunction..................................................................733 DTC41 ECM Not Registered................................................................................735 DTC42 Serial Data Circuit Malfunction (Between Immobilizer Control Module and ECM)......................736 DTC43 ECU Code Not Matched..............................................................................737 Inspection of Immobilizer Control Module and Its Circuit................................................738 On-Vehicle Service..........................................................................................740 Precautions in Handling Immobilizer Control System......................................................740 Immobilizer Control Module..............................................................................741 Coil Antenna............................................................................................741 How to Register Ignition Key............................................................................742 Procedure after Immobilizer Control Module Replacement..................................................743 Procedure after ECM Replacement.........................................................................744 Special Tools...............................................................................................745 Copyright.......................................................................................................747 Bookcover....................................................................................................... 0
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